bds4 s i s m - magna products

BDS4 SERIES

INSTALLATION AND SETUP MANUAL

M93100 - Issue 2Old Number

New Number MB4001H

© Copyright 1993, Danaher Motion Kollmorgen. All rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Danaher Motion Kollmorgen except under written agreement.

All rights reserved. No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means (electronic, mechanical, photocopying, recording, or otherwise) without the written permission from the publisher. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damager resulting from the use of the information contained herein.

This document is proprietary information of Danaher Motion Kollmorgen, furnished for customer use ONLY. No other uses are authorized without written permission from Danaher Motion Kollmorgen.

Information in this document is subject to change without notice and does not represent a commitment on the part of Danaher Motion Kollmorgen. Therefore, information contained in this manual may be updated without notice due to product improvements, etc., and may not conform in every respect to former issues.

This product is covered by U. S. Patents:

4,447,771 4,479,078 4,490,661 Other (foreign patents pending)

U. L. is a trademark of Underwriter's Laboratories. N. E. C. is a trademark of the National Electric Code. Kollmorgen GOLDLine, BDS4, BDS5, and PSR4/5 are trademarks of Danaher Motion Kollmorgen.

Dangerous voltages, currents, temperatures, and energy levels exist in this product and in the associated servomotor(s). Extreme caution should be exercised in the application of this equipment. Only qualified individuals should attempt to install, setup, and operate this equipment. Ensure that the motor, drive, and the end-user assembly are all properly grounded per NEC requirements.

Danaher Motion Kollmorgen

Phone: 1-800-777-3786 or (815) 226-3100 Technical Support Fax: (540) 731-5679

BDS4 FOREWORD

FOREWORD

The commitment to quality at Industrial Drives is ourfirst priority. In all aspects of our business: research,development, product design and customer service,we strive to guarantee total quality. This pledge isfounded on a solid history of innovative technologicalachievements dating back to 1948. One of the finesttributes to that achievement can now be seen at theSmithsonian which has on display the first stellarinertial navigation system developed by Dr. CharlesStark Draper. This system contains the first modelsof torque motors built by the founding organization ofIndustrial Drives. During the period of 1948 to 1960,our "firsts" in the industry numbered more than adozen; they ranged from the simple but invaluable(such as the direct-drive DC torque motor and movietheater projection motors) to the exotic: submarineperiscope drive motors for the U.S. Navy, electricdrives, Curtis Wright electric brake coils, andnumerous other innovations.

For more than a decade, Industrial Drives (known inthe early days as part of Inland Motor Division ofKollmorgen) has continued to enhance itssophisticated engineering solutions to pioneer newproduct development.

The results of these and other efforts has encouragedsome of the most significant innovations in the servoindustry. We developed the application of servomotors and drives in the Machine Tool market. Wewere the first with water-cooled servos, the integralbrake, the flux forcing concept and the brushlessmotor. We developed the electronically commutatedelectric car motor. Industrial Drives pioneered rare

earth magnet development for the servo motorindustry.

Between 1974 and 1980, Industrial Drives continuedto lead the industry in servo application innovations.Our commitment to engineering excellence neverwaivered. In fact, that commitment grew strongerwith the development of brushless submarine andsubmersible motors (visiting the Titanic graveyard),multi-axis electronic drives and antenna pedestaldrives (delivering unprecedented accuracy andrevolutionizing the entire industrial automationprocess).

The decade of the 1980's brought continuedadvancements in technology and penetration of newmarkets requiring precise motion control. Already inthe fifth generation of brushless products, IndustrialDrives continues to lead the way with digital servopositioning capability and our newest motor offering,the GOLDLINE Series, incorporating the very latesthigh-energy, rare earth magnets (neodymium ironboron). Once again, we are setting the standards thatothers only hope to duplicate. Recentlyacknowledged by the Frost and Sullivan Foundation,a leading market specialist in the motion controlindustry, Industrial Drives and its parent, KollmorgenCorporation, continue to rank first in servotechnology.

Other achievements? Yes, too many in fact tomention. Each achievement stands as a testimony tothe committed quality and excellence in designtechnology. This constancy of purpose is unyieldingin an era of rapidly changing technology.

A-63542……….. Motor ConnectionA-83908……….. Purchase Spec. for Mini-Fit, Jr.Series ConnectorA-83909……….. Purchase Spec. for Mini-Fit, Jr.Series TerminalsA-84385……….. Outline & Dimension PSR4/5 - 12 & 20 AmpA-93031……….. Outline & Dimension PSR4/5 - 50 & 75 AmpA-93092……….. PRS4/5 50A / 75A (with & without Soft Start) Simplified SchematicA-93112……….. Outline & Dimension BDS4 - 55 AmpA-93141……….. Wiring & Mounting DiagramER-20A-93156……….. Outline & Dimension BDS4 - 30 & 40 AmpA-93231……….. BDS4 Wiring DiagramA-93314……….. Wiring & Mounting Diagram ER-21A-93315……….. Wiring & Mounting Diagram ER-22A-93316……….. Wiring & Mounting Diagram ER-23A-93369……….. GOLDLINE Amplifier Assembly Guide for Resolver CablesA-93408……….. PRS4/5 12A / 20A Simplified SchematicA-93409……….. PSR4/5 Internal SchematicA-93414……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (30, 40, & 55 Amp)A-93421……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (3 thru 20 Amp)A-93538……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (3 thru 20 Amp)A-93539……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (30, 40, & 55 Amp)A-93540……….. GOLDLINE Amplifier Assembly Guide for Resolver CablesA-93541……….. BDS4 Direction Limit Wiring DiagramA-93567……….. Outline & Dimension BDS4 - 3 & 6 AmpA-93568……….. Outline & Dimension BDS4 - 20 AmpA-93572……….. Outline and Dimension BDS4 - 10 AmpA-93656……….. Mounting Hole Pattern BDS4, BDS5, PSR4/5A-93700……….. DC Bus Cable Assembly for BDS4/5 & PSR4/5A-93703……….. Mounting Hole Pattern BDS4B-84929……….. BDS4 & BDS5 Logic Cable AssemblyC-84113……….. BDS4 Simplified SchematicC-84723……….. PSR4/5 Simplified SchematicC-84724……….. PSR4/5 Internal SchematicC-93185.……….BDS4 - OPT2/3A Pinout OptionsD-93179……….. BDS4 - OPT2/3A

List of Drawings BDS4

List of Drawings

v

XXXXX

BDS4 CHAPTER 1 - SYSTEM DESCRIPTION

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CHAPTER 1

SYSTEM DESCRIPTION

1.1 INTRODUCTION

The information in this chapter will enable you tounderstand the product's basic functions and features.These concepts will allow you to apply them to yourown unique applications.

1.2 PRODUCT DESCRIPTION

Industrial Drives' BDS4 product lines are 3-phasesine wave, brushless motor controllers. They arefully regenerative four-quadrant, bi-directionalvelocity loop amplifiers designed to be used withIndustrial Drives' high performance B seriespermanent magnet brushless motors.

Although the BDS4 is basically an analog servoamplifier, it contains a microprocessor to implementIndustrial Drives' patented Torque Angle Controlfunction for maximum system performance.

The BDS4 amplifier modules are available in sizes of3, 6, 10, 20, 30, 40 and 55 amps RMS/phasecontinuous. The modular design provides theflexibility for multiple axes to share a common powersupply requiring no input isolation transformer.

The PSR4/5 Power Supply modules are available insizes of 12, 20, 50 and 75 amps RMS/phasecontinuous (AC input line ratings).

Numerous Industrial Drives B Series motors withvarious diameters, stack lengths, and windings arealso available.

1.3 FEATURES

Highlighted design features are:

• Modular construction maximizing serviceability.

• Two-part plug connectors interfacing betweenthe BDS4, PSR4/5, and other equipment.

• Routine adjustments accessible from the front ofthe BDS4.

• High frequency (20 kHz) motor current ripple forquality servo performance, higher efficiency, andless audible noise.

• Differential velocity or current command input.

• Voltage programmable current limit input.

• A removable compensation board containing allthe components that make the BDS4 compatiblewith a particular motor.

• Protection against thermal overload indicates anyovertemperature conditions. The BDS4 isprotected against peak current overloads by acurrent foldback circuit. Also, it is protected

CHAPTER 1 - SYSTEM DESCRIPTION BDS4

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from logic bus out-of-tolerance conditions andmotor stator short circuit conditions, both line-to-line and line-to-ground.

• Drive-Up contact closes indicating the amplifieris ready for input command signal; opens on faultconditions.

• Standard PSR4/5 Power Supply units contain aSoft Start function and a dynamic bus dischargefunction.

• The 12 and 20 amp PSR4/5 units have, asstandard, 40 watts of internal shunt regulation.There are optional versions available having noshunt regulator. Other options have externallymounted power resistance allowing shuntregulation of up to 700 watts. The shuntregulator is protected from excessive peakcurrent by fuse. It is also protected fromexcessive duty, if duty cycle exceeds a presetlimit, by shunt overload shutdown circuit.

• The 50 and 75 amp PSR4/5 shunt regulation isaccomplished with externally mounted powerresistor(s) with ratings from 500 to 2000 watts asstandard. Special units may be ordered for evenhigher power. The shunt regulator is protectedfrom excessive peak current by a thermaloverload relay. It is also protected fromexcessive duty, if duty cycle exceeds a presetlimit, by shunt overload shutdown circuit.

• Diagnostic LED indicators located on the frontpanel on both the BDS4 and the PSR4/5modules.

• Either a 12-Bit Parallel Position InformationCard or an Encoder Equivalent Output Card asavailable options.

1.4 THEORY OF OPERATION

The BDS4 brushless servo system consists of threemain components:

1. PSR4/5 - Power Supply Module

2. BDS4 - Amplifier Module

3. B - Brushless Motor

All of the compensation components necessary tomatch a BDS4 amplifier to a particular motor such as,current loop compensation, velocity loopcompensation, and torque angle compensation, arelocated on the removable BDS4 COMPcompensation board located inside the BDS4amplifier.

The TL (Test Limits and Modification) Sheetcontains the compensation component values andsuch information as maximum operating speed, peakcurrent limits, etc. that are assigned to each BDS4system.

Only motors having the identical base model numbermay be run on the BDS4 amplifiers. If a motorhaving a different base motor model number is to berun on a BDS4, the BDS4-COMP compensationboard must be altered or changed accordingly. TheBDS4 must remain the same current and voltagerating.

1.4.1 PSR4/5 Power Supply Module

Refer to Figure 1.1 for a quick reference of thePSR4/5 and drawings A-93409, A-93408 and A-93092 for precise details.

The PSR4/5 Power Supply Module is divided intofour (4) main sections:

1. The Unregulated Logic Bus, supplied by theControl AC line input voltage (normallysingle-phase 115 VAC), is described inSection 4.2.

2. The 310/140 Main DC Bus is supplied bythe main AC line input voltage (normallythree-phase 230 VAC or single-phase 115VAC).

3. The Soft-Start Feature (standard) resistorlimits the inrush current (to charge-up theMain Bus Capacitors) to a specific amountas listed in Appendix D.

4. The Shunt Regulator (regeneration) sectionincludes circuitry which monitors the mainbus. During deceleration profiles, the motorbasically operates as a DC generator andpumps energy back into the main buscausing the bus to rise. The Shunt Regulator


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limits the voltage rise during thedeceleration periods.

• 12 and 20 AMP Models:

The shunt regulator (regeneration) resistorload is fuse protected. If the shunt regulator

is held on for too long, the shunt regulatorpower transistor fails, or the shunt regulatorload resistor becomes shorted, the fuse willblow and cause the Fault Contact on thePSR4/5 to open and the BLOWN REGENFUSE LED to become illuminated.

Figure 1.1. BDS4 and PSR4/5 (Low Current Models shown)


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The shunt regulator also includes a dutycycle limit circuit to protect againstexcessive load resistor heating. If theaverage duty cycle limit is exceeded, theregeneration circuitry will become disabled,the Fault Contact will open, and theOVERLOAD LED will become illuminated.To reset this fault, remove and reapply allinput line power; bus capacitors mustcompletely discharge.

• 50 and 75 AMP Models:

WARNING

The thermal overload outputcontacts must be connectedinto a shut down circuit (EStop string, etc.) to drop themain power or a possible firehazard will exist. Refer toDrawing A-93231.

The shunt regulator (regeneration) resistor isprotected by a thermal overload relay. If theresistor rating is exceeded or if the shuntregulator transistor fails, the thermaloverload output contacts will openindicating an IMMEDIATE need to removethe main power.

1.4.2 BDS4 Servo Amplifier Module

Refer to Figure 1.1 for a quick reference of theBDS4's features.

The BDS4 Servo Amplifier is divided into four (4)main sections:

1. Fault Diagnostics monitor various signalleads. When a fault condition occurs thefault circuit will become latched, the BDS4will become internally inhibited, theappropriate red LED will becomeilluminated, and the Drive-Up contact willopen indicating that the BDS4 is in itsInhibit mode.

2. The Input/Output interface circuitry isdivided into two functions:

(A) Signals to and from the motor andBDS4.

These signals are associated with themotor system resolver. A 7.0 kHzexcitation signal is generated in theBDS4 and sent to the resolver. Tworesolver feedback signals (sine andcosine) are received by the BDS4 andprocessed by an R/D (resolver-to-digital) converter. The R/D unitgenerates a digital position word used inelectronically commutating the motorand an analog velocity (internal tach)signal to close the servo loop.

(B) Signals to and from the signalsource (PLC, CNC, etc.) and BDS4.

There are numerous signals that mayinterface between the signal source(PLC, CNC, etc.) and the BDS4. Theseinputs and modes of operation differwith each application.

3. The BDS4 consists of a single velocity loopand three inner current loops. To giveprecise velocity control, the velocity loop isnormally configured as a proportional, plusan integral, plus a derivative gain servo loop.The output of the velocity loop is the currentcommand for the three microprocessor-based current loops.

The heart of the BDS4 is its microprocessorwhich receives and processes the currentcommand (velocity error) signal from theoutput of the velocity loop circuit, theposition information from the resolver-to-digital converter, and several other signals.After receiving the velocity error, themicroprocessor generates three sinusoidalcurrent commands. These currentcommands are forwarded to the threeproportional plus integral current loops, onefor each of the three motor phases.

The microprocessor is the key element in theIndustrial Drives patented torque angletechnique. The microprocessor varies thephase of the currents with respect to motor


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flux and significantly improves the motorspeed-vs-torque profile.1

4. The outputs from the three current loopcircuits are converted into a 10 kHz pulsewidth modulation scheme. The modulationis such that the 10 kHz PWM results in 20kHz current ripple in the motor, resulting invery quiet motor operation.

The PWM switching signals are opticallycoupled to the power stage gate drivehardware for complete electrical isolation.The BDS4 uses IGBT's (Isolated GateBipolar Transistors) for the output powerstage; allowing high frequency operation.

1.4.3 Brushless DC Motor

The Industrial Drives' B Series brushless motorsfeature the latest in permanent magnet technology,utilizing high energy Neodymium-Iron-Boron alloys.These brushless motors consist of permanent magnetrotors and three-phase Y-stator windings. This placesthe heat producing member on the outside where itcan best dissipate heat. These motors (depending onsize) are either four- or six-pole motors. Since theyare brushless motors, there are no commutators orassociated brushes. The motors run as synchronousmotors, meaning the rotor speed is the same as thespeed (frequency) of the stator's rotating magneticfield. The feedback device is a brushless resolver,mounted internally as part of the overall motorconstruction. Another available option is the integralbrush tachometer. For more information, refer to theInstallation and Service Manual, B Series BrushlessMotors M-89031.

1.4.4 Power Up/Down Sequencing

First, apply the 115 VAC control voltage. Second,apply the main AC voltage. Third, check for faultsand then enable the BDS4. The AC line inputvoltages may be removed in any sequence.

1 The BDS4A/V sine-wave controller allows a wider range speedbecause it has the ability to electronically change the anglebetween the rotor flux and the stator flux—commonly referred toas torque angle. Industrial Drives, A Kollmorgen Division,Patented Numbers 4,447,771; 4,479,078; and 4,490,661.

1.4.5 With Soft-Start Circuit(Standard)

1. Only the Control AC line input voltage isapplied.

a. The logic bus comes up.

b. A power-up reset pulse is generated inthe BDS4.

c. If no faults (other than main busundervolts) are present after the power-up reset pulse is generated (a delay ofone second) then the drive is ready to beenabled. However, there can be nomotor movement until the main AC lineinput voltage is applied.

2. The Main AC line input voltage is applied.

a. The soft-start circuit charges the MainDC bus capacitors in the PSR4/5through a current limiting resistor.

b. The shunt regulator regenerationcircuitry is switched from dynamic busdischarge to regular mode.

c. The undervoltage fault in the BDS4 isnow cleared (after approximately 3/4sec. delay), and if jumper J21 isinstalled on the BDS4-COMP Board,the Drive Ready LED will becomeilluminated and the Drive-Up contact inthe BDS4 (between Pins 10 and 20 ofConnector C1) will close. The BDS4 isready to be enabled and will enableonce the enable input is activated.

3. Only the Main AC line input voltage isremoved.

a. Approximately 30 msec. after the MainAC line input voltage is removed, theshunt regulator is switched fromregulate to the dynamic bus dischargemode, and the main DC bus power isdischarged.

b. The shunt regulator circuit isdeactivated.


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c. The Drive-Up contact within the BDS4will open due to Bus undervolts.

4. Only the Control AC line input voltage isremoved.

a. The Drive-Up contact in the BDS4 willopen. The BDS4 is immediatelydisabled.

b. Operation of the soft-start/dynamic busdischarge and other circuits within thePSR4/5 will not be affected.

c. The PSR4/5 fault contact will open.

1.4.6 Without Soft-Start Circuit orDynamic Bus Discharge (Optional)

1. Only the Control AC line input voltage isapplied.

a. The logic bus comes up.

b. A power-up reset pulse is generated inthe BDS4.

c. If no faults (other than main busundervolts) are present after the power-up reset pulse is generated (a delay ofone second) then the drive is ready to beenabled. However, there can be nomotor movement until the main AC lineinput voltage is applied.

2. The Main AC line input voltage is applied.

a. The soft-start circuit charges the MainDC bus capacitors in the PSR4/5through a current limiting resistor.

b. The shunt regulator regenerationcircuitry is switched from dynamic busdischarge to regular mode.

c. The undervoltage fault in the BDS4 isnow cleared (after approximately 3/4sec. delay), and if jumper J21 isinstalled on the BDS4-COMP Board,the Drive Ready LED will becomeilluminated and the Drive-Up contact inthe BDS4 (between Pins 10 and 20 ofConnector C1) will close. The BDS4 isready to be enabled and will enableonce the enable input is activated.

3. Only the Main AC line input voltage is removed.

a. The DC bus will bleed down slowlyafter approximately five minutes.

b. The shunt regulator is deactivated.

c. The Drive-Up contact within the BDS4will open.

4. Only the Control AC line input voltage isremoved.

a. The BDS4 will be immediatelydisabled.

b. The BDS4 Drive-Up contact will open.

c. The PSR4/5 fault contact will open.

1.5 TYPICAL SYSTEM DIAGRAM

Figure 1.2 illustrates a typical system with all of themajor components.

BD

S4

CH

AP

TE

R 1 - S

YS

TE

M D

ES

CR

IPT

ION

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Figure 1.2. Typical System Diagram

BDS4 CHAPTER 2 - INSTALLATION

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CHAPTER 2

INSTALLATION

2.1 INTRODUCTION

The information in this chapter will familiarize youwith the safety information, unpacking andinspection, installation requirements, assemblyprocedures and electrical connections for installingthe BDS4. A checklist is provided at the end of thischapter to insure proper installation.

2.2 SAFETY INFORMATION

The purpose of this section is to alert you to possiblesafety hazards associated with this equipment and theprecautions you can take to reduce the risk ofpersonal injury and damage to the equipment.

Safety notices in this manual provide importantinformation. Read and be familiar with theseinstructions before attempting installation, operation,or maintenance. Failure to observe these precautionscould result in serious bodily injury, damage to theequipment, or operational difficulty.

The safety-alert symbols are illustrated in Figure 2.1.When you see these symbols in this manual, be alert

to the potential for personal injury. Follow therecommended precautions and safe operatingpractices included with the alert symbols.

"Warning" refers to personal safety. They alert youto potential danger or harm. Failure to followwarning notices could result in personal injury ordeath.

"Caution" directs attention to general precautions,which if not followed, could result in personal injuryand/or equipment damage.

"Note" highlights information critical to yourunderstanding or use of these products.

2.3 CONVENTIONS

To assist you in understanding the material in thismanual, conventions have been established toenhance reader comprehension. Explanations ofthese conventions are as follows:

• Safety warnings, cautions, and notes presentmaterial that is important to user safety. Be sureto read any safety notices you see as they couldprevent equipment damage, personal injury, oreven death to you or a co-worker.

• Bold text highlights other important informationthat is critical to system operations.

WARNING CAUTION NOTE

Figure 2.1. Safety-Alert Symbols

CHAPTER 2 - INSTALLATION BDS4

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• CAPITALIZED text stresses attention to thedetails of the procedure.

• Underlined text emphasizes crucial words insentences that could be misunderstood if theword is not recognized.

2.3.1 BDS4 vs. BDS4V vs. BDS4A &PSR4/5 vs. PSR4/5A

The BDS4, BDS4V and the BDS4A differ inaccording to the following:

BDS4 Original Standard Configuration

BDS4V Industrial Standard Configuration

BDS4A U.L. 508 Approved Configuration

The BDS4 is the original amplifier developed byIndustrial Drives. It was followed by a value analysisversion, the BDS4V. The BDS4A was laterdeveloped and submitted to UL for approval.

In a similar manner, the PSR4/5 and PSR4/5A followthis scheme:

PSR4/5 Original Standard Configuration

PSR4/5A UL 508 Approved Configuration

This indicates that the BDS4A and PSR4/5A meet allthe safety standards set by the UnderwriterLaboratories. Where differences occur betweenmodels, special instructions will be indicated in thismanual. For the purpose of referencing all amplifiersand power supplies, the nomenclatures BDS4 andPSR4/5 will be used. Check your model number toverify your model.

2.3.2 Model Numbering Scheme

All Industrial Drives components contain a model andserial number printed on a black and gold tag on thefront panel. The model number identifies how theequipment is configured. Refer to Appendix C forthe model number scheme tables. These tablesexplain what the model configurations are. Youshould verify that the model numbers represent theequipment desired for your application. Also verifythe compatibily between components of the servosystem.

2.3.3 Abbreviations

CCW Counter ClockwiseCW ClockwiseDIFF CMD Differential CommandD/L Direction LimitGC Goldline CableGCS Goldline Cable SetLED Light Emitting DiodeNEC National Electrical CodeP/N Part NumberR/D Resolver-to-DigitalRegen RegenerationTL Test LimitsUL Underwriters Laboratories

2.4 UNPACKING AND INSPECTION

CAUTION

Electronic components inthis amplifier are staticsensitive. Use properprocedures when handlingcomponent boards.

Upon receipt of the equipment, closely inspectcomponents to ensure that no damage has occurred inshipment. If damage is detected, notify the carrierimmediately.

Carefully remove packing material and remove theequipment from the shipping container. Do notdispose of shipping materials until the packing list hasbeen checked. Parts that are contained within theshipment, but not physically attached to theequipment, should be verified against the packing list.If any parts are missing, notify Industrial Drives atonce.

2.5 INSTALLATION REQUIREMENTS

Proper installation and field wiring are of primeimportance when considering the application of servoamplifiers. Many problems may be avoided ifinstallation of the equipment is done properly. Usersshould familiarize themselves with and followinstallation and wiring instruction in addition to allapplicable codes, laws and standards. Pay specialattention to the following topics when installingIndustrial Drives' equipment.


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2.5.1 Environmental Considerations

The environment that this equipment is placed in canhave dramatic effects on its operation. IndustrialDrives recommends that the BDS4 and PSR4/5 beoperated and stored under the following conditions:

• Operating Temperature: 0° C to 45° C

• Storage Temperature: -20° C to 70° C

• Humidity: 10% to 90% (Non Condensing)

2.5.2 Enclosures

It is suggested that the BDS4 and PSR4/5 be mountedin a cabinet or other suitable enclosure to protectthem from physical and environmental damage.Refer to Appendix D for complete systemdimensions.

CAUTION

Allow sufficient clearance forthe large "regenerative" heatproducing resistor(s)mounted at the upper edgeof the PSR4/5 unit and theexternally mounted regen(shunt regulator) powerresistor(s).

2.6 ASSEMBLY

The BDS4 and PSR4/5 are both constructed prior toshipping from the factory. The only assemblyrequired is the mounting of the devices.

2.6.1 Mounting

Refer to the drawing of your model system inAppendix F for outline and dimensions. Be sure tolook at the proper drawing for mountingmeasurements.

The PSR4/5 and BDS4 modules should be mountedin the vertical position. To minimize cross talk andenhance air flow, maintain a minimum of 20millimeters (0.75 in.) on either side of each unit andat least 40 millimeters (1.5 in.) of unobstructed spaceabove and below the units.

Depending on the continuous current ratings of theBDS4 and PSR4/5 modules, a total of six (6)amplifiers may be mounted with a single powersupply. However, the maximum number of BDS4amplifiers mounted on either side of the PSR4/5power supply module must not exceed four (4).

Mounting combinations for the PSR4/5 and BDS4modules are as follows:

• PSR4/5-X12; a maximum of four (4) BDS4amplifiers sequentially or "split mounted"(amplifiers are mounted on both sides of thePSR4/5) at either side of the PSR4/5 indescending order of continuous current ratings.

• PSR4/5-X20; a maximum of four (4) BDS4amplifiers sequentially or "split mounted" ateither side of the PSR4/5 in descending order ofcontinuous current ratings.

• PSR4/5-X50; a maximum of six (6) BDS4amplifiers ("split mounted" only) to either side,not to exceed four (4) amplifiers on a side,mounted in descending order of continuouscurrent ratings.

• PSR4/5-X75; a maximum of six (6) BDS4amplifiers ("split mounted" only) to either side,not to exceed four (4) amplifiers on a side,mounted in descending order of continuouscurrent ratings.

NOTE

Refer to The drawing of yourmodel system in Appendix Ffor the Mounting Hole Patterninformation.

CAUTION

Allow sufficient clearance forthe large "regenerative" heatproducing resistor(s). Theinternal resistors aremounted at the upper edge ofthe PSR4/5 unit. Theexternally mounted regen(shunt regulator) powerresistor(s) are mountedabove the PRS4/5A unit.


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2.6.2 Mounting the ExternalRegeneration Resistor(s)

WARNING

External regenerativeresistors are a shock hazard!

Mount these resistorsproperly! Enclose theseresistors to protect personneland equipment!

CAUTION

External regenerationresistors can becomeextremely hot!

Allow safe clearance aroundthe resistor(s) enclosures.Proper ventilation must beprovided.

Some models of PSR4/5 use an externally mountedregen (shunt regulator) resistor. The resistor kitincludes mounting hardware and, depending on themodel, a thermal overload relay to be wired in withthe resistors. A suitable enclosed location outside theequipment cabinet needs to be set aside for mountingthese components while observing the heat and shockrequirements of these resistors.

2.7 ELECTRICAL CONNECTIONS

WARNING

Dangerous voltages,currents, temperatures, andenergy levels exist in thisproduct and in theassociated servo motor(s).Extreme caution should beexercised in the applicationof this equipment. Onlyqualified individuals shouldattempt to install, set-up,and operate this equipment.Ensure that he motor, drive,and the end-user assemblyare properly grounded perNEC requirements.

To facilitate wiring, the BDS4 amplifiers must bemounted next to the PSR4/5 power supply module indescending order according to their continuouscurrent ratings. Refer to Section 2.6.

NOTE

In order to adhere to suitableengineering practice, the ACcontrol voltage (115 VAC forthe logic bus) must beapplied first to activate thecontrol and fault logiccircuits prior to applying themain AC voltage.

Follow these precautions:

1. Observe all notes on the wiring diagram.

2. All motor stator leads, signal input leads,resolver leads, encoder leads, and tachometerleads must be shielded.

3. Twist all AC leads to minimize electromagneticemissions (noise).

4. Avoid running signal leads (must be shielded)in close proximity to power leads, motor statorleads, or other sources of electromagneticnoise.

5. Minimize lead lengths as much as possible.

6. Connect the BDS4 system according to theSystem Wiring Diagram; pay close attention tothe grounding scheme.

7. Provide adequate stress relief for cables.

NOTE

The notes on BDS4 WiringDiagram (A-93231) givespecific wiring details.

Thermal overload protection for the motor is notprovided within the PSR4/5 or the BDS4 and must beprovided externally. Refer to the National ElectricalCode for proper sizing of overload protection.

With the exception of the hook-up of the motor, themain input voltage, and the main Bus+ and Bus- DCvoltage, all interface wiring between the BDS4,


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PSR4/5, and other equipment is accomplished byconnectors supplied with the BDS4 and PSR4/5 units.

The input/output connections are grouped byconnector or terminal block. They are input/output,motor, resolver, AC main power and control voltages,main DC bus, and unregulated DC voltages.

To connect the power bus of the PSR4/5 to the BDS4amplifiers the following is suggested:

• For PSR4/5-X12 modules, use 600 VACinsulated 14 AWG or larger wire.

• For PSR4/5-X20 modules, use 600 VACinsulated 10 AWG wire.

• For PSR4/5-50 and PSR4/5-75 modules, use600 VAC insulated 8 AWG or larger wire.

Captive screws are used in the power terminals of thePSR4/5-X12 module, PSR4/5-X20 module, and the 3amp thru the 20 amp BDS4 amplifiers. Do notattempt to remove these screws to use ring terminals.Use locking spring terminals similar to Hollingsworth#XSS20945S or #SS20947SF for 16 and 14 AWGwire and #XSS20836 or #SS20832F for 12 and 10AWG wire.

2.7.1 Recommended Torque forElectrical Connections

Table 2.1 displays the recommended torque valuesfor terminal block and grounding connecting points.All torques are measured with the wire or terminal lugunderneath the screw head.

2.7.2 Grounding Scheme

To prevent shock hazard to personnel and to ensureproper operation of the servo system, the BDS4,PSR4/5, and the servo motor must be groundedaccording to NEC specifications. Each BDS4 andPSR4/5 have at least two grounding screws on thefront of the chassis.

NOTE

Provisions of the NationalElectrical Code with respectto grounding should befollowed. These precautionsgenerally deal with theground loop currents arisingfrom multiple ground paths.Only one ground path shouldbe used.

One of the screws on the chassis of the PSR4/5should go to earth or machine ground. The othershould be connected to the adjacent BDS4 groundscrew along with the ground wire from the motor.The free ground screw on the BDS4 chassis shouldthen be connected to the next BDS4, etc.

For grounding to machine or earth ground, a screwlug should be attached to the ground screw or stud onthe PSR4/5 or BDS4. A torque of 12 in.lb. forground screws and 20 in.lb. for ground studs isrecommended. Also refer to the National ElectricalCode (NEC) or UL standard 486B for recommendedtorque's.

Table 2.1. Torque Values

CONNECTINGPOINTS

BDS4-3-20AMP UNITS

BDS4-30-55AMP UNITS

PSR4/5-12-20AMP UNITS

PSR4/5-50-75AMP UNITS

AC Input Screws 12 in. lb. 20 in. lb. 12 in. lb. 20 in. lb.

DC Bus Screws 12 in. lb. 20 in. lb. 12 in. lb. 20 in. lb.

Motor ConnectingScrews

12 in. lb. 20 in. lb.

External RegenScrews

12 in. lb. 20 in. lb.

Ground Screws 12 in. lb. 20 in. lb. 12 in. lb. 20 in. lb.


2-6

2.7.3 Connecting the AC InputVoltages

The Main AC Input Voltage, either single- or three-phase, should be connected at La, Lb, and Lc on thepower terminal block located on the front of thePSR4/5 unit. The PSR4/5 is not line-phase sensitive.When using the 12 or 20 amp PSR4/5 with single-phase main power, the input lines may be connectedto any two (2) terminals La, Lb, or Lc.

The Control AC input voltage should be wired toConnector C1 - Pins 2 and 3 on the PSR4/5 and fromConnector C1 - Pins 5 and 6 of the PSR4/5 toConnector C4 - Pins 1 and 2 (fan units only) on theBDS4.

NOTE

Connector C4 is present onlyon BDS4 Amplifiers that havecontinuous ratings of 20 ampsand above.

2.7.4 Connecting the PSR4/5 FaultOutput Contact (Connector C1)

Pins 1,4 Fault Contact

The Fault Output Contact closes when power isapplied to the PSR4/5. This contact opens on a faultcondition within the PSR4/5 only.

The pinouts for C1 are listed in Figure 2.2. Refer toNote 2 of the BDS4 Wiring Diagram (A-93231) forfurther information concerning the PSR4/5 FaultOutput Contact.

2.7.5 Connecting the Unregulated DCVoltage to the BDS4 (Connector C3)

The wiring between the BDS4 Connector C3 and thePSR4/5 Connector C2 (unregulated voltage) is inTable 2.2 and the pinouts are in Figure 2.3.

2.7.6 Connecting the Main DC BusVoltage

Refer to notes 4 and 6 on BDS4 Wiring Diagram A-93231 for details concerning the hook-up of the Bus+ and Bus - circuits between the PSR4/5 and theBDS4 amplifiers.

WARNING

Failure to observe correctpolarity will result in damageto the PSR4/5 and BDS4.

2.7.7 Connecting the ExternalRegeneration Resistor(s)

If an external regeneration resistor is specified,connecting points are provided on the PSR4/5 PowerSupply Unit (refer to Notes 3 and 10 on BDS4Wiring Diagram A-93231).


2-7

Table 2.2. BDS4 Unregulated DC Voltages (C3)

VOLTAGE CURRENT

BDS4CONNECTOR C3

PINS

PSR4/5CONNECTOR C2

PINS

+18 V Nominal(+17 V to +26.5 V)

NO LOAD 1, 5 1, 5

-18 V Nominal(-17 V to -26.5 V)

NO LOAD 2, 6 2, 6

COMMON --- 3, 7 3, 7

10 V Nominal(+9 V to +14 V)

NO LOAD 4, 8 4, 8

+ 14.5 V MIN. 1 AMP ON PSR4/5 12 OR 20 AMP UNITS

2 AMP ON PSR4/5 50 OR 75 AMP UNITS

1, 5 1, 5

- 14.5 V MIN. 1 AMP ON PSR4/5 12 OR 20 AMP UNITS


2, 6 2, 6

COMMON --- 3, 7 3, 7

+ 6.5 V MIN. 2 AMP ON PSR4/5 12 OR 20 AMP UNITS


4, 8 4, 8

+18 VDC 5 1 +18 VDC

-18 VDC 6 2 -18 VDC

COMMON 7 3 COMMON

+10 VDC 8 4 +10VDC

Figure 2.3. BDS4 (C3) & PSR4/5 (C2)(Nominal, No Load Voltages)

FAULTCONTACT

4 1 FAULT CONTACT

115 V OUTPUT 5 2 115 V INPUT

115 V OUTPUT 6 3 115 V INPUT

Figure 2.2. PSR4/5 (C1)


2-8

2.7.8 Connecting the BDS4Input/Output (Connector C1)

The following descriptions tell the user which inputsand modes of operation are available, enable the userto identify the appropriate connecting points onConnector C1, and help the user decide which inputsand modes of operation to use. The pinouts are listedin Figure 2.4.

Pins 15,16,17 Common

These pins provide commons (returns) betweenexternal equipment (numerical controls, etc.) and theBDS4.

Pins 4,5,6 Shield

These pins provide termination points for cableshields. To insure there are no ground loops in theshield common, connect only one end, butt andinsulate the other end.

Pin 11 DIFF CMD HI

Pin 1 DIFF CMD LO

Differential velocity or current command input +10V full scale, 20 K Ohm input impedance. Should beshielded.

_____Pin 2 Enable

Allows the BDS4 to be enabled or disabled withoutremoving the main power. When a circuit is closedbetween Pin 2 and common, the BDS4 will be putinto the Drive-Up mode. Opening the circuit putsthe BDS4 into the Inhibit mode [internal 20 K Ohmpull-up resistor to +12 VDC] (Green LEDindicated).

_____Pin 3 Reset

Allows any latched fault circuit exceptOVERVOLTS or OVERCURRENT faults to bereset by toggling Pin 3 to common. It has a 20 KOhm pull-up resistor to +12 VDC.

__________Pin 7 Output Fault

Open collector signal (logic low) to indicate thateither an overcurrent or overvoltage fault hasoccurred in the Power Stage of the amplifier. 25 masink capabilities, 30 VDC Max (red LED indicated).

_______Pin 8 Foldback

Open collector signal (logic low) to indicate that theamplifier has started to reduce peak current due toexcessive loading, 25 ma sink capabilities, 30 VDCmax (red LED indicated).

________Pin 9 Overtemp

This output will transition low to indicate the BDS4amplifier is being subjected to an excessivetemperature condition. Open collector, logic low, 25ma sink capability, 30 VDC max (red LEDindicated).

_______Pins 10,20 Drive-Up

DIFF HI 11 1 DIFF LO

AUX IN 12 2________ENABLE

_______I LIMIT 13 3

_____RESET

______________TORQUE HOLD 14 4 DIFF SHIELD

COMMON 15 5 SHIELD

COMMON 16 6 SHIELD

COMMON 17 7_______________OUTPUT FAULT

I MONITOR 18 8___________FOLD BACK

SPEED MONITOR 19 9__________OVERTEMP

DRIVE-UP 20 10 DRIVE-UP

Figure 2.4. BDS4 Connetor (C1)


2-9

The Drive-Up contact closure (internally) indicates tothe outside world that the BDS4 amplifier is in theDrive-Up mode; or when the contact is open, itindicates the Inhibit mode. The contact is rated at115 VAC at 2 amps (green LED indicates DriveReady).

The Drive-Up relay acts in conjunction with theEnable circuit in one of two possible modes ofoperation as determined by optional jumper J21. Todetermine which mode of operation is being utilized,refer to J21 on the TEST LIMITS SHEET.

1. Drive-Up Mode

J21 is not installed on the BDS4-COMP Board.

Apply power.

When the Enable input circuit is activated (pulledlow), the internal Drive-Up contact will close and thegreen Drive Ready LED will become illuminated.However, when the Enable input circuit is notactivated, or a fault occurs, the internal Drive-Upcontact will be open and the green Drive Ready LEDwill be off indicating that the BDS4 is in the InhibitMode.

If a fault occurs within the BDS4, the Drive ReadyLED will turn off and the Drive-Up contact will openand remain open regardless of the state of the Enableinput circuit.

2. O.K. to Enable/Drive-Up Mode

JR21 is installed on the BDS4-COMP Board(Standard).

Apply power.

When there are no faults present, the internal Drive-Up contact will be closed and the green Drive ReadyLED will be illuminated indicating that the BDS4 isOK-TO-ENABLE. However if there is a faultpresent, the Drive-Up contact will be open and theDrive Ready LED off indicating that the BDS4 is in afault mode. In this case, activating the Enable inputcircuit will not enable the BDS4.

Pin 12 Aux IN

This is an additional single ended input to thevelocity loop. This input may be used in adaptive

mode applications or used as the tach input forintegrally motor-mounted tachometer generators.

Pin 13 I Limit

The Current Limit input allows access to the CurrentLimit circuitry providing a means by which inputsmay be applied for adaptive control applications.

This single ended input may also be used to adjust thepeak current limit of the amplifier from 7.5% to100% of its rating. A positive voltage from 0 VDC to7.5 VDC corresponds to 7.5% to 100% respectively.Also, a resistor to common may be used to programthe current limit with 75% of I peak = 8.6 K Ohm,50% of I peak = 3.3 K Ohm. The Current LimitAdjustment Pot may also be used to adjust the peaktorque of the motor to the desired level.

Pin 14 Torque Hold

The BDS4 may be converted from a constant velocityamplifier to a constant torque amplifier (at stall only)by closing a circuit between Pin 14 and common (viainternal 20 K Ohm pull-up resistor). The velocityloop operational amplifier is maintained at unity gainwhile in this mode of operation.

Pin 18 I Monitor

There is a direct relationship between the signalappearing at this output and actual motor current. ADC voltmeter placed between Pin 18 and common,calibrated in either current or torque, can be used toestimate the constant load levels placed on the motor.The current scale factor at Pin 18 is 8V = Peak RMScurrent rating of the BDS4 (3 K Ohm outputimpedance). This output is for reference only. Itsaccuracy decreases as current decreases: +/- 4% atpeak current, +/-9% at continuous current, +/- 12% at1/2 continuous current.

Pin 19 Speed Monitor

There is a direct relationship between the signalappearing at this output and actual motor speed. ADC voltmeter (or other instrument) placed betweenPin 19 and common, calibrated in RPM, can serve asa means by which speeds may be monitored. Refer tothe TL Sheet for the scale factor in volts/RPM (8volts = maximum speed) as listed on the TL Sheet forthe particular motor/amplifier combination (3K Ohmoutput impedance).


2-10

2.7.9 Connecting the Motor

NOTE

B SERIES MOTORS have athermostat switch wired to theresolver connector at themotor.

BR SERIES MOTORS have athermostat switch wired to thestator connector at the motor.

CAUTION

The motor thermostat switchis an automatic resettingdevice and should beconnected directly into alatched (locked out) powerdown type circuit.

WARNING

Incorrect motor resolverphasing can cause erraticoperation, runaway, ordamage to the system.

Terminate Pins A, B, C, D, E, and F of the resolverconnector at Connector C2 on the BDS4 as shown byFigures 2.5 and 2.6. Also see the BDS4 WiringDiagram (A-93231) and the appropriate motor HD(hook-up) drawing or Motor Connection Diagram (A-63542). Use cables with three (3) independently

shielded pairs for the resolver.

The leads of the three-phase synchronous motor arebrought out to Pins A, B, and C of the motorconnector. Pin D is ground for the motor. Refer toFigure 2.7 for pin connections.

Terminate Pins A, B, and C of the motor connector toMa, Mb, and Mc, respectively, on the power terminalblock located on the front of the BDS4 amplifier.Terminate Pin D at the BDS4 chassis ground screw.Refer to Wiring Diagram (A-93231) and theappropriate motor HD (hook-up) drawing.

The optional integrally-mounted tachometer isbrought out to Pins R and S on the resolver connectorfor both the B and BR series motors. Pin R (Tach Hi)should be terminated at Connector C1 - Pin 12 (AuxIn) of the BDS4. Pin S (Tach Lo) should beterminated at Connector C1 - Pin 15 (common) of theBDS4. The tachometer is an option and is notinstalled on most motors.

2.8 INSTALLATION CHECKLIST

Refer to BDS4 Wiring Diagram (A-93231).

Before applying power to the PSR4/5 and BDS4,check the following items to ensure proper operation:

CAUTION

To prevent damage to theequipment, the motor andresolver, the AC line voltage,and the DC bus voltages mustbe connected as indicated byBDS4 Wiring Diagram (A-93231).

SIN HI 7 1 SIN LO

SIN SHIELD 8 2 COS SHIELD

COD HI 9 3 COS LO

REF LO 10 4 REF HI

SPARE SHIELD 11 5 REF SHIELD

N/C 12 6 N/C

Figure 2.5. BDS4 (C2)


2-11

2.8.1 Checking the Motor andResolver Wiring

Disconnect both the motor stator and resolverconnectors from the motor. Using an ohmmeter,check the continuity of each motor stator leadbetween the motor stator connector pin and theBDS4. Using an ohmmeter, check the continuity ofeach motor resolver lead between the motor resolverconnector pin and the BDS4. The motor stator andresolver leads should be connected according toBDS4 Wiring Diagram (A-93231). There are noother options for connecting the motor stator andresolver leads.

2.8.2 Checking the AC Line Voltages

Open the circuit breaker or remove the fuses in theMain AC lines that are connected to the PSR4/5 at La,Lb, and Lc. Remove Connector C1 from the PSR4/5,and remove (if present) Connector C4 from theBDS4.

Apply only the AC main power. Use an ACvoltmeter to check and record the 1- or 3-phase line-to-line voltage at the circuit breaker or fuse holders.Remove power. Note the model number of thePSR4/5 and refer to Appendix B to confirm thecorrect Main AC voltage level.

Figure 2.6. Motor Resolver Connections


2-12

Apply only the AC control power. Use an ACvoltmeter to check and record the single-phasevoltage at Connector C1 of the PSR4/5. Removepower. Note the model number of the PSR4/5 andrefer to Appendix B to confirm correct Control ACvoltage level.

If the voltage levels are within the specificationslisted in Appendix B, proceed with the Check-Outprocedure.

Close the circuit breaker or re-install the fuses for theMain AC input power. Re-install Connectors C1 andC4 (if present).

2.8.3 Checking the DC Bus Voltages

WARNING

Allow sufficient time (afterremoving power from thesystem) for the voltage tobleed down before connectingor disconnecting wires at thebus.

Remove power.

Remove the Bus+ and Bus- leads from the PSR4/5power terminal block. Remove mating Connector C2from the PSR4/5.

Apply power.

Figure 2.7. Armature Motor Connections


2-13

Check and record the Main DC Bus Voltage output at(+) with respect to (-) on the PSR4/5 terminal blockaccording to Section 2.1. Check and record theunregulated DC voltage levels at Connector C3 of thePSR4/5. They should be ± 17 to 26.5 and + 9 to 14.5VDC per Section 2.7.5.

Remove power.

Note the model number of the PSR4/5 and refer toSection 2.1 to confirm DC voltage levels.

If the voltage levels are within the specificationslisted in Appendix D, proceed.

WAIT FOR THE BUS TO BLEED DOWN andreconnect the B(+) and B(-) leads to the powerterminal block of the PSR4/5. Be careful toreconnect the leads with the proper polarity. Re-install Connector C2 on the PSR4/5.

CAUTION

Failure to observe correctpolarity will result in damageto the PSR4/5 and BDS4.

BDS4 CHAPTER 3 - OPERATION

3-1

CHAPTER 3

OPERATION

3.1 INTRODUCTION

The information in this chapter will enable you tobecome familiar with system components and theirdependence upon one another. Also, it will help youensure each component is configured and functionsproperly. At this point, all safety stops and otherprecautions should be in place and working properly.Be prepared to stop the machine if necessary.

3.2 INITIAL START-UP

You should now be ready to supply power to test theservo systems functions and features. Work with onlyone axis section at a time. Confirm all other BDS4amplifiers are inhibited, meaning the enable circuitsare open (high).

CAUTION

Incorrect servo-to-positionloop phasing can causeexcursion oscillations, orrunaways.

Appropriate precautions should be taken to stop themachine if necessary. Limit switches and safetydevices should be in place.

CAUTION

Unloaded motors,compensated for a largeinertia mismatch, maybecome unstable when thesystem is activated. Refer tothe test limits (TL) sheet forstable load inertia range. Ifthe system becomesunstable, remove the powerimmediately.

3.3 SEQUENCE OF OPERATIONS

This section contains a basic start-up sequence thatshould be followed the first time the servo system isinitialized. READ THIS ENTIRE SECTIONBEFORE PERFORMING ANY OF THESEPROCEDURES. When you apply power to thesystem, pay special attention to the LEDs on theBDS4 front panel. The CONTROL VOLTS andDRIVE READY (green) LEDs should be illuminated.This indicates that the system is functioning properly.Should a FAULT (red) LED remain on for more thana instant, immediately disconnect power and consultChapter 5 - Troubleshooting.

1. Apply power. Enable only one BDS4.Observe the action of the machine. If thedirection of the motor shaft rotation is reversed

CHAPTER 3 - OPERATION BDS4

3-2

(motor shaft turns in the wrong direction),remove power.

2. Reverse the input to the BDS4 at DIFF CMDHI and DIFF CMD LO at Connector C1, Pins 1and 11. DO NOT ATTEMPT TOREVERSE DIRECTION OF ROTATIONBY INTERCHANGING MOTOR LEADSAND/OR RESOLVER LEADS.

NOTE

If the motor is commanded tomove and does not respond,turn the command scaleadjustment several turns CW.

If the servo system performed properly, then readChapter 4 - Maintenance for adjustments and otherinformation that may be helpful in adapting yoursystem to your own applications.

BDS4 CHAPTER 4 - MAINTENANCE

4-1

CHAPTER 4

MAINTENANCE

4.1 INTRODUCTION

The information in this chapter will enable you tomaintain the systems components ensuring smooth,efficient operation of the motor. Adjustments to thesystem are broken in three (3) categories: Set-Up,Response and Application Dependent, and DesignTolerance. These adjustments allow the user to tailorthe BDS4 to their specific applications.

4.2 PREVENTATIVE MAINTENANCE

CAUTION

Preventative maintenance tothis equipment must beperformed by qualifiedpersonnel familiar with theconstruction, operation, andhazards involved with theapplication.

CAUTION

Electronic components in thisamplifier are static sensitive.Use proper procedures whenhandling component boards.

Preventative maintenance should be performed withthe BDS4 system out of operation and disconnectedfrom all sources of power.

4.2.1 Transient Voltages

NOTE

All transient-producingdevices must be properlysuppressed.

Solid state controls of the BDS4 may be affected bytransient voltages. These voltages are in excess of thespecified voltage for any given circuit. When thesepeak voltages occur, even for less than a second,permanent damage to the BDS4 can occur.

In order to help avoid transient voltages that mayinterfere with electronic circuit functions within thePSR4/5 and BDS4, all switched inductive devices ortheir wiring (solenoids, relay coils, starter coils, etc.)must be suppressed. A 220 ohm, 1/2 watt resistor inseries with a 0.5 micro farad, 600 volt capacitor orequivalent is suggested.

4.2.2 Surge Current

Excessive current greater than that of the specifiedlimits of the PSR4/5 and BDS4 can cause permanentdamage to the system. Current limiting means arerecommended to protect from these currents.

CHAPTER 4 - MAINTENANCE BDS4

4-2

CAUTION

If the short circuit inrushcurrent generated by thepower source is in excess of5000 amps RMS symmetricalcurrent, an isolationtransformer or line inductormust be utilized in theincoming power circuit.Failure to observe thisprecaution could result indamage to, or destruction ofthe PSR4/5 and BDS4.

Input transformers step up or step down input voltageand can be either autotransformers or isolationtransformers. Isolation transformers help eliminatethe following:

• Damaging AC line voltage transients reachingthe PSR4/5 and BDS4.

• Damaging currents which may develop if apoint inside the PSR4/5 or BDS4 becomesgrounded.

4.2.3 Electrical Noise

The low levels of energy in the BDS4 control circuitsmay cause them to be vulnerable to electrical noise.Sources of electrical noise are those pieces ofequipment that have large, fast changing voltages andcurrents when they switch on and off. These deviceshave the capability of inducing critical current andvoltage transients on their respective power lines.These transients must be accommodated for withnoise immunity provisions.

Electrical noise is prevented with the same methodsas Surge Current and Transient Voltages. However,there are other methods of preventing electrical noise.Such as:

• Maintain physical separation between electricalnoise sources and the BDS4 amplifier.

• Maintain physical separation between electricalnoise sources and the BDS4 control wiring.This can be accomplished by using separateconduits or wiring trays for control wiring andpower wiring.

• Use twisted-pair wiring for control circuits ofthe BDS4.

• Follow good grounding practices when wiringthe PSR4/5 and BDS4. Be careful not to createa grounding loop with multiple ground paths.Follow the NEC's provisions on grounding.

4.2.4 Radio Frequency Energy

NOTE

This equipment generatesradio frequency energy.

This equipment uses, and can radiate radio frequencyenergy and must be installed and used in accordancewith this installation and service manual in order toprevent possible interference with radiocommunications or other electronic equipment.

4.3 PERIODIC MAINTENANCE

Periodic maintenance must be performed by qualifiedpersonnel familiar with the construction, operation,and hazards involved with the BDS4 and itsapplication. Power should be disconnected during allmaintenance procedures.

4.3.1 Ventilation

The PSR4/5 and BDS4 should be mounted verticallyto allow maximum ventilation of the components.This configuration allows the heat generated by thecomponents to vent through the top and draft incooler air through the bottom. The top and bottom ofthe components are vented to allow this drafting tooccur. These ventilation passages should be keptopen. If the PSR4/5 requires auxiliary cooling withfans, inspect the fans on a regular basis.

4.3.2 Grounding Integrity

The method employed for grounding or insulating theequipment from ground should be checked to assureits integrity on a regular basis. This check should beperformed with the power off and the testingequipment grounded.


4-3

4.4 ADJUSTMENTS

NOTE

Adjust pots with properadjustment tool.

DO NOT FORCE.

The adjustments are classified into three categories:

1. Set-Up Adjustments - Adjustments that arenecessary at installation (accessible at the frontof the BDS4).

Motor System Resolver Phasing andAlignment - Should be checked the first time(if I.D. cables are not used).

Balance Adjustment.

Command Scale Adjustment.

2. Response and Application DependentAdjustments - These adjustments addversatility to the BDS4 and allow it to be"tailored" to specific applications (accessible atthe front of the BDS4).

Stability Adjustment.

Current Limit Adjustment.

3. Design Tolerance Adjustments - Factory setand sealed adjustments should never requirecustomer adjustment (internal adjustments).

Current Sensor Offset Adjustments - Pots AZand CZ.

Resolver Excitation Adjustment - Pot OSCG.

FACTORY ONLY ADJUSTMENTS - PotsR/DTR, R/DG, and R/DZ.

4.4.1 Set-Up Adjustments

At equipment start-up, make these adjustments.

4.4.1.1 Balance Adjustment (WithinPosition Loop)If a monitor or readout displays Following Error,adjust Balance Pot for zero Following Error at zerospeed.

Optional: Monitor DIFF CMD HI with respect toDIFF CMD LO with a DC voltmeter. Command zerospeed from the Numerical Controller. AdjustBalance Pot for zero volts on the meter.

4.4.1.2 Balance Adjustment(Automatic or Manually OperatedMachines)Monitor DIFF CMD HI with respect to DIFF CMDLO with a DC voltmeter. With the input signal atzero volts or with the input shorted to common, adjustBalance Pot for zero speed.

4.4.1.3 Command Scale Adjustment(Within Position Loop)If the following error is displayed by monitor orreadout, command a slow feed rate and adjustCommand Scale Pot for the proper amount ofFollowing Error at that speed.

4.4.1.4 Command Scale Adjustment(Automatic or Manually OperatedMachines)Turn the Command Scale Pot fully CCW. Apply aninput signal level which equals maximum desiredmotor speed in RPM. Adjust Command Scale PotCW for maximum desired motor speed. DO NOTEXCEED THE MAXIMUM MOTOR SPEEDTHAT IS LISTED ON THE TL SHEET FORTHE SYSTEM.

Refer to the Test Limits Sheet (TL) to identify themaximum scaling of input signal. Maximum + 10volts is standard.

4.4.2 Response and ApplicationDependent Adjustments

These adjustments allow versatility in altering thedynamic response of the BDS4 system as needed.

CHAPTER 4 - MAINTENANCE BDS4

4-4

When altering the response of the system, it may benecessary to adjust both the STABILITY and theCURRENT LIMIT adjustments.

4.4.2.1 Stability AdjustmentIn many cases, the Stability Pot will not need to beadjusted and may be left in its fully CCW position.

However, this pot can be used to improve thedynamic response of the servo loop, by adjusting theDynamic (AC) Gain. To adjust the AC Gain to theproper point, use an oscilloscope to monitor theinternal tach signal at the SPEED MONITOR testpoint with respect to A-COM (refer to Figures 1 and3). Use a second channel of the scope to monitor thecurrent signal at the I MONITOR test point, also withrespect to A-COM (refer to Figures 1 and 3). Turnthe STABILITY Pot fully CCW. Apply a step input(rapid) command signal. While accelerating anddecelerating the motor at approximately 25% ofmaximum speed, adjust the STABILITY Pot CWand notice the tach and current wave forms at theSPEED MONITOR and I MONITOR test points.Watch for indications of instability (i.e., ringing) inthe wave forms while accelerating and deceleratingthe motor. Turn the STABILITY Pot CCW until thetendency to go unstable disappears.

4.4.2.2 Current Limit AdjustmentThe maximum peak current limits are set at thefactory and can not be increased above the level listedon the Test Limits sheet (TL). Although the peakcurrent limits cannot be increased above the specifiedvalue, they may be decreased.

To reduce the peak current limit level, apply a stepinput command signal. Use an oscilloscope tomonitor the I-MONITOR test point (refer to Figures1 and 3). Accelerate and decelerate the motor.Adjust the CURRENT LIMIT Pot for desired peakcurrent limit. The current scale factor at the IMONITOR test point is 8V = Peak RMS rating of theBDS4 (refer to Section 2.2 for Peak Rating andSection 4.1 for more information on this signal).

4.4.3 Design Tolerance Adjustments(Factory Set and Sealed)

NOTE

These adjustments should notbe made in the field. Theyhave been factory set andsealed and should neverrequire adjustment.

The following procedures are to be followed only ifthe seals are broken.

4.4.3.1 Resolver ExcitationAdjustmentInhibit the BDS4 by opening the Enable input circuit.

Using an oscilloscope, monitor REFERENCE HIGHat TC2-1 (refer to Figure 1 or 3). Adjust Pot OSCG(inside the BDS4) for 12 volts peak-to-peak. Thissignal should be 7.0 kHz ±500 HZ.

4.4.3.2 Current Sensor OffsetAdjustmentsUsing a digital DC voltmeter, monitor TC4-1. AdjustPot AZ (inside the BDS4) for minimum voltage level.Using the digital voltmeter, monitor TC4-3 and adjustPot CZ (inside the BDS4) for minimum voltage level.Refer to drawing C-84113.

4.4.3.3 Motor System ResolverAlignment

NOTE

This procedure applies only tothe system resolver, not theapplication (position loop)resolver.

The motor system resolver is properly aligned at thefactory and should never require realignment.However, this procedure is included here in the event(motor repair, etc.) the resolver should ever needrealignment.

In order for the following test to be valid, the motorand resolver phasing must be correct. If there is anydoubt as to whether the motor and resolver are wiredcorrectly, refer to Section 4.6 and check the motorand resolver wiring.


4-5

The motor system resolver alignment can beconfirmed by conducting the following test:

1. Remove power. Disconnect the motor shaftfrom any mechanical load.

2. Connect a small jumper between TC1-3 andTC1-4 (refer to Figures 1 and 3). While in thismode (resolver zeroing test mode), theFOLDBACK LED will become the resolveralignment indicator.

3. Apply power. DO NOT ENABLE THE BDS4.If necessary have a colleague observe theFOLDBACK LED. The FOLDBACK LEDwill be either off or slowly blinking. Slowlyrotate the motor shaft until the FOLDBACKLED blinks at its fastest rate (rotate slowly thenpause, giving the circuitry time to react). Thecloser the resolver is to being correctly aligned,the faster the LED will blink. The LED shouldbe somewhere between one pulse per secondand fully illuminated when it blinks at itsfastest rate.

CAUTION

Remove hand from motorshaft before enabling. Theshaft will jerk into positionwith some force.

4. Enable the BDS4 by pulling Connector C1-Pin2 on the BDS4 to common. The internalsoftware of the BDS4 will cause phase Ma tohave zero current. The Mb and Mc phases willhave equal, but opposite, currents causing themotor shaft to align itself in a neutral position.The FOLDBACK LED should be fullyilluminated indicating correct alignment of theresolver. No further attempt at alignment isnecessary. Resolver alignment is correct.

5. If, however, the LED does not become fullyilluminated as indicated in Step 4 above,proceed with the alignment procedure.

Inhibit the BDS4.

Remove power.

Remove the end plate (cover) from the rearend of the motor. The shaft-mountedframeless resolver will be in sight.

The frameless resolver rotor is slid forwardonto the motor shaft and secured by a largelock nut. This part of the resolver should notbe disturbed.

6. Loosen, but do not remove, the two servoclamp screws holding the resolver statorsecure. DO NOT MOVE THE POSITION OFTHE MOTOR SHAFT.

7. Apply power. If necessary, repeat Step 3above. Enable the BDS4. Slowly rotate theresolver stator (outside element) while acolleague watches the FOLDBACK LED onthe front of the BDS4 amplifier.

If the LED does not become fully illuminated,turn the resolver stator in the oppositedirection. Continue to rotate the resolverstator until the LED becomes fully illuminated.If the correct alignment position is passed, theLED will blink more slowly. When the LEDbecomes fully illuminated, discontinue turningthe resolver stator and tighten the two servoclamp screws.

Inhibit the BDS4.

Remove power.

8. Repeat Steps 3 and 4 above.

9. Inhibit the BDS4.

Remove power.

Remove the jumper from the test points.

Replace the motor end cover.

4.4.3.4 Factory Only Adjustments

WARNING

Do not adjust Pots R/DTR,R/DG, and Pot R/DZ. Thesepots are set and sealed at theFactory and cannot beadjusted in the field. If thesepot seals are ever broken,return the complete BDS4amplifier to the Factory foralignment.

BDS4 CHAPTER 5 - TROUBLESHOOTING

5-1

CHAPTER 5

TROUBLESHOOTING

5.1 INTRODUCTION

The information in this chapter will enable you toisolate and resolve common system hardwareproblems. The troubleshooting methods in thismanual isolate each component from the system untilthe problem is resolved.

5.2 FIELD SERVICEABILITY

CAUTION

Dangerous voltages exist inthis equipment. Also, motortemperature may exceed 100°°°°C. Extreme caution shouldbe exercised whentroubleshooting thisequipment. Only qualifiedindividuals should attempt toinstall, setup, operate, ortroubleshoot this equipment.

The BDS4 and PSR4/5 are designed to promoteminimum down time situations. Due to the compactpackage size and to the fact that there are few user-serviceable components on the modules, it isrecommended that they be replaced if they cease tofunction properly. Return the modules, in theirentirety, to Industrial Drives for repair.

The only user-serviceable items on the PSR4/5 arethe output line fuses in the control DC voltage supplyand (in the 12 and 20 amp units) the shunt regulatorregeneration load resistor fuse.

CAUTION

To preserve the level ofprotection for the product asdesigned, replacement fusesmust be the exact same styleand ampere rating as thoseoriginally installed.

The BDS4 modules may be interchanged, providedthe following guidelines are adhered to:

1. The BDS4 modules must be the same rating.

2. The motors being controlled must bear thesame model number.

3. In the event the motors have different modelnumbers, the BDS4-COMP Board must bearthe model number of the motor beingcontrolled or the BDS4-COMP Board must bealtered, per TL (Test Limits Sheet) to make theBDS4 compatible with the motor.

Before beginning the troubleshooting process,consider the following points:

I. There are four (4) distinct areas within which afault may occur:

CHAPTER 5 - TROUBLESHOOTING BDS4

5-2

A. External Interface (Circuitry external to, butconnecting to, the BDS4.)

B. BDS4 Amplifier Module

C. PSR4/5 Power Supply Module

1. Main DC bus voltage

2. Control DC bus voltages

3. Shunt Regulator Regeneration Circuitry

4. Soft-Start/Dynamic Bus DischargeCircuitry

D. Motor

1. Resolver

2. Tachometer (Optional)

II. There are only two (2) basic fault characteristicsto be considered:

A. The motor exhibits very low torque or istotally inoperative.

B. The motor is erratic or exhibits an impropermode of operation.

5.3 SYMPTOMS AND CORRECTIONS

If the motor does not respond or responds in amanner other than with smooth operation, removepower and troubleshoot the system with the followingguidelines. Also refer to Table 5.1 for more impropermotor operation symptoms.

5.3.1 The Motor Exhibits Very LowTorque or is Totally Inoperative

Prerequisites for motor movement:

1. The BDS4 and PSR4/5 must be wiredcorrectly, per BDS4 Wiring Diagram(A-93231).

2. All power must be present.

3. The BDS4 must be in the Enable mode, asindicated by the green CONTROL VOLTS,ENABLE, and DRIVE READY LED's.

4. A command signal (other than zero volts) mustbe present at the input of the BDS4.

5. Command Scale Adjustment should not befully CCW.

6. Fault circuits must not be activated. Faultmodes are identified by red LED's located onthe front of the BDS4 and PSR4/5 modules.

5.3.2 The Motor is Erratic or Exhibitsan Improper Mode of Operation.

Prerequisites for proper motor operation:

1. Proper grounding scheme must be provided.The motor ground wire should be connected asshown by BDS4 Wiring Diagram A-93231.

2. Motor armature leads must not be run inconduit or wire ducts with any signal carryingconductors.

3. The resolver leads, tach leads (when used), andmotor armature leads must be wired accordingto BDS4 Wiring Diagram A-93231.

4. The motor system resolver must be set at itszero point (refer to Section 4.4.3.3).

5. Stability Adjustment should not be fully CW.

6. The motor should be loaded with its specifiedload inertias — see TL sheet for stable loadinertia range. Otherwise, the BDS4 maybecome unstable.

5.3.3 BDS4-3, 6, 10, 20, 30, 40 and 55AMP STATUS LED'S

The status of the BDS4 modules is indicated by three(3) Green and six (6) Red LED's. Refer to Figure 5.1for the LED configuration. The diagnosticinformation indicated by these LED's is listed asfollows:


5-3

• Approximately one second after all power isapplied, the green CONTROL VOLTS LED onthe front of the BDS4 module should becomeilluminated to indicate that the Control AC lineinput voltage is applied.

• When the Enable input circuit of the BDS4 isclosed, the green ENABLE LED shouldbecome illuminated indicating that the BDS4 isnow in the enabled mode.

• No fault (red) LED's should be illuminated.

• The green DRIVE READY LED may or maynot be illuminated, depending on whether ornot jumper J21 is installed on the BDS4-COMP Board.

The red FOLDBACK LED will become illuminatedduring any situation where the RMS current exceedsthe continuous rating of the BDS4 (peak current isallowed for only 2.0 seconds). The LED indicatesthat the peak current of the BDS4 is automaticallybeing reduced to the RMS continuous rating. Oncethe current demand is reduced, the FOLDBACK

circuit will reset and the LED will turn off. This LEDacts only as an indicator.

If the red OVERTEMP LED becomes illuminated,the BDS4 will become latched in the Inhibit modeindicating an overheated BDS4 heatsink.

When the red OVERCURRENT LED becomesilluminated, it indicates an overcurrent conditionusually due to a shorted load (motor), wiring, orBDS4 power stage transistor. The BDS4 will becomelatched in the Inhibit mode.

If the red OVERVOLTS LED becomes illuminated,the BDS4 will become latched in the Inhibit mode,indicating the presence of excessive main DC busvoltage.

When the red UNDERVOLTS LED becomesilluminated, the BDS4 will be put into the Inhibitmode (but not latched) indicating the main DC Bus isinsufficient or absent.

If the red OVERSPEED LED becomes illuminated,the BDS4 will become latched in the Inhibit modeindicating that the motor has obtained an excessivespeed, or the resolver cable is miswired or has anintermittent connection.

The Fault Output contact located within the PSR4/5power supply module will not be affected by anyfaults occurring within the BDS4.

More diagnostic information about the BDS4 is listedin the Table 5.2.

5.3.4 PSR4/5-12 and 20 Amp StatusLED's

The status of the PSR4/5-12 and 20 amp modules isindicated by one (1) Green, one (1) Yellow, and two(2) Red LED's. Refer to Figure 5.2 for the LEDconfiguration. The diagnostic information indicatedby these LED's is as follows:

• Approximately 0.25 seconds after the mainpower is applied, the green DC BUS LED willbecome illuminated to indicate the presence ofvoltage on the main DC bus capacitors.Voltage indication may range in magnitudefrom over 300 VDC, during normal operationwith AC line voltage applied, to below 50 VDC

Figure 5.1. BDS4 Status LED's


5-4

when the line voltage is removed but the buscapacitors have not completely discharged.

� The yellow REGEN LED is for monitoringpurposes only. When this LED becomesilluminated, the shunt regulator regenerationcircuit is active. No fault is indicated.

� The red OVERLOAD LED will becomeilluminated in the event the shunt regulatorregeneration circuit experiences an overloadcondition. The Fault Output contact will alsoopen.

� The red BLOWN REGEN FUSE LED willbecome illuminated and the Fault Outputcontact will open in the event the shuntregulator regeneration fuse blows.

� Faults occurring within the PSR4/5 will causeits Fault Output contact to open.

More diagnostic information about the PSR4/5 12and 20 Amp LED's is listed in Table 5.3.

5.3.5 PSR4/5-50 and 75 Amp StatusLED's

The status of the PSR4/5-50 and 75 amp models isindicated by one (1) Green, one (1) Yellow, and one(1) Red LED. Refer to Figure 5.3 for the LEDconfiguration. The diagnostic information indicatedby these LED's is as follows:

� Approximately 0.5 seconds after the mainpower is applied, the green DC BUS LED willbecome illuminated to indicate the presence ofvoltage on the main DC bus capacitors.Voltage indication may range in magnitudefrom over 300 VDC, during normal operationwith AC line voltage applied, to below 50 VDC

when the line voltage is removed but the buscapacitors have not completely discharged.

� The yellow REGEN LED is for monitoringpurposes only. When this LED becomesilluminated, the shunt regulator regenerationcircuit is active. No fault is indicated.

� The red FAULT LED, when illuminated,indicates an excessive heatsink temperaturewithin the unit due to an overload conditionand may also indicate excessive ambienttemperature.

� Faults occurring within the PSR4/5 will causeits Fault Output contact to open.

More diagnostic information about the PSR4/5 50and 75 Amp LED's is listed in Table 5.4.

5.3.6 BDS4 or PSR4/5 ResetProcedures

To reset the OVERVOLTS and OVERCURRENTfault latches within the BDS4 and all fault latcheswithin the PSR4/5 power supply units, remove all ACline input voltage for at least five (5) minutes or untilthe power stage capacitors are fully discharged. Allother fault latches within the BDS4 amplifiers may bereset by toggling the RESET input circuit to commonor by removing and reapplying the input voltage asdescribed previously.

The thermal overload relay with the PSR4/5 50 and75 amp modules External Regen Resistor(s) isnormally furnished and set for "HAND" resetoperation. In the event of excessive shunt regulatoractivity, its auxiliary contact will open. (THISCONTACT MUST BE WIRED INTO THE E-STOPSTRING OR AN EQUIVALENT SHUNT DOWNCIRCUIT.) The thermal overload relay may be resetby pushing in the reset rod located in the top of the unit.

Figure 5.2. PSR4/5 12,20 Status LED's

Figure 5.3. PSR4/5 50,75 Status LED's


5-5

Table 5.1. Improper Motor Operation Troubleshooting

SYMPTOM PROBABLE CAUSE

Incorrect Direction of MotorShaft Rotation

(a) Invert input command signal at Connector C1-1 and 11.

CAUTION

DO NOT ATTEMPT TO REVERSE DIRECTION OF ROTATION BYINTERCHANGING MOTOR LEADS AND/OR RESOLVER LEADS.

Motor Drifts Slowly with ZeroInput

(a) Adjust balance Pot for zero speed (in position loop for zeroFollowing Error or zero input signal).

Uncontrolled ExcessiveSpeed

(a) Motor and/or resolver leads incorrectly connected.

(b) BDS4 backwards in position loop (motor shaft turns in wrongdirection).

(c) Incorrect alignment of system resolver (refer to Section 4.4.3.3).

(d) Defective BDS4-COMP Board.

Motor Erratic (a) Motor and/or resolver leads incorrectly connected.

(b) Incorrect alignment of system resolver (refer to Section 4.4.3.3).

(c) Improper grounding scheme (noise corrupting the input signal,tach signal when used, and/or resolver signals).

System Unstable (a) Stability Pot improperly adjusted.

(b) Unloaded motor (load motor with TL specified load inertia).

(c) Incorrect compensation. Check BDS4-COMP Board against TLSheet.


5-6

Table 5.2. BDS4 Status LED Indicator Troubleshooting


1) Control Volts LED(Green) Not Illuminated

(a) Control AC line input voltage out of spec or had a momentaryinterruption.

(b) Unregulated logic bus not applied to BDS4 from PSR4/5 due todefective wiring or being miswired (fuses inside of PSR4/5 may beblown).

(c) Defective logic bus supply in BDS4 or PSR4/5 or blown logic busfuse.

(d) Defective BDS4.

2) Enable LED (a) Enable input circuit not pulled low.

(Green) Not Illuminated (b) Defective BDS4.

3) Drive Ready LED (a) BDS4 faulted (see Red LED's).

(Green) Not Illuminated (b) BDS4-COMP Compensation Board not installed or misinstalled.

(c) Reset input activated (active low).

(d) Defective BDS4.

4) Foldback LED(RED) Illuminated

(a) BDS4 in resolver alignment test mode (refer to Section 4.4.3.3).

(b) Excessive RMS current causing BDS4 I2t protection circuit toactivate. Reduce motor duty cycle.

5) Overtemp LED (RED) (a) Excessive heatsink temperature due to overload or high ambienttemperature.

(b) Defective BDS4.

6) Overcurrent LED (RED) Illuminated

(a) When this LED becomes illuminated, an overcurrent condition[usually due to a shorted load (motor stator winding), shorted statorwiring, or a shorted BDS4 power stage component] is indicated. If thisLED becomes illuminated, remove the power and disconnect themotor. Reapply power. If the BDS4 comes up without this LEDbecoming illuminated, suspect a faulty motor or motor stator wiring. Ifthe BDS4 comes up with the LED illuminated, suspect a faulty BDS4power stage.

7) Overvolts LED (RED) (a) This LED will become illuminated if the Main DC Bus risesabove 230 VDC for 115 VAC system, 430 VDC for the 230 VACsystem. This can happen due to PSR4/5 fault or inadequately sizedshunt regulator regeneration resistor.

8) Undervolts LED (RED) (a) This LED will become illuminated if the Main DC Bus isinsufficient or absent.

9) Overspeed LED (RED) (a) In the event the motor obtains an excessive speed, theOVERSPEED fault circuit will activate, latch the BDS4 in the inhibitmode, and this LED will become illuminated.

(b) Miswired or intermittent resolver cable.


5-7

Table 5.3. PSR4/5 12 & 20 Amp Status LED Indicator Troubleshooting


1) DC BUS LED (Green)Not Illuminated

(a) Main DC Bus insufficient or not present. AC input powernot applied; check input line fuses.

2) Regen LED (Yellow)Illuminated or Flashing

(a) Not a fault condition. Indicates regeneration circuitactivity.

3) Overload LED (Red)Illuminated

(a) Main DC Bus voltage excessively high due to high MainAC line input voltage.

(b) Shunt regulator regeneration circuit overload.

(c) Defective PSR4/5.

4) Blown Regen Fuse LED (Red)Illuminated

(a) Shunt regulator regeneration resistor sized too small.

(b) Defective PSR4/5.

Table 5.4. PSR4/5 50 &75 Amp Status LED Troubleshooting


1) DC Bus LED (Green)Not Illuminated

(a) Main DC Bus insufficient or not present. AC input power notapplied; check input line fuses.

2) Regen LED (Yellow)Illuminated or Flashing

(a) Not a fault condition. Indicates regeneration circuit activity.

3) Fault LED (Red)Illuminated

(a) Excessive heatsink temperature due to overload or high ambienttemperature.

(b) Defective PSR4/5.

NOTE

Consult Factory if fault occurs during hard deceleration.

BDS4 CHAPTER 6 - SPARE PARTS

6-1

CHAPTER 6

SPARE PARTS

6.1 INTRODUCTION

The information in this chapter will enable you toobtain spare parts for your Industrial Drivesequipment. Use these tables to order any parts thathave become defective or that are required forspecific configurations. Ordering instructions arealso provided.

6.2 RECOMMENDED SPARE PARTS

It is recommended by Industrial Drives that you haveavailable for use in your BDS4 and PSR4/5, the partslisted in Tables 6.1 and 6.2. It is also very importantto note that there are no user serviceable parts oneither component other than those fuses andconnector kits listed.

Table 6.1. BDS4 Spare Parts List

DESCRIPTION PART NUMBERQUANTITYPER UNIT

Connector Kit BDS4C-100 (3, 6, and 10 amp models) 1

BDS4C-101 (20 amp model) 1

BDS4C-200 (30, 40, and 55 amp models) 1

CHAPTER 6 - SPARE PARTS BDS4

6-2

Table 6.2. PSR4/5 Spare Parts List

DESCRIPTIONPSR4/5MODEL PART NO.

QUANTITYPER UNIT

CONNECTOR KIT ALL12 AND 20A

PSR4/5C-100 1

CONNECTOR KIT ALL50 AND 75A

PSR4/5C-200 1

CONTROL VOLTSFUSES

ALL12 AND 20A

A-78896-008 (1.5 AMP)FUSE 99, 102

2

A-78896-012 (4 AMP)FUSE 126

1

CONTROL VOLTSUSES

ALL 50 AND75A

A-78896-012 (4 AMP)FUSE 64,65

2

A-78896-016 (8 AMP)FUSE 24

1

SOFT-STARTFUSE

115 VAC12 AND 20 AMP

A-80552-007 (5 AMP)FUSE 121

1

SOFT STARTFUSE

ALL 230 VAC12 and 20 AMP

A-80552-001 (10 AMP)FUSE 121

1

SOFT-STARTFUSE

ALL 50 AND 75 AMP A-78896-017 (10 AMP)IN-LINE

1

REGEN FUSE -112, 120 A-80552-013 (7 AMP)FUSE 132

1

REGEN FUSE -112-02-120-02

A-80552-001 (10 AMP)FUSE 132

1

REGEN FUSE -212, 220 A-80552-009 (8 AMP)FUSE 132

1

REGEN FUSE -212-01, -220-01 A-80552-002 (12 AMP)FUSE 132

1

REGEN FUSE 220-03 A-80552-003 (15 AMP)FUSE 132

1

CAUTION

ALL FUSES MUST BE REPLACED WITH EXACT SAME VALUE AND STYLE OR THEYWILL NOT BE EFFECTIVE.

BDS4 CHAPTER 6 - SPARE PARTS

6-3

6.3 ORDERING INSTRUCTIONS

If you need to order parts for the BDS4 and/orPSR4/5, you can order them through your localdistributor. For a complete list of Industrial Drivesrepresentatives contact us directly at:

Danaher Motion Customer Support201 Rock RoadRadford, VA 24141U.S.A.

Telephone: 1-800-777-3786 (815) 226-3100

FAX: (540) 731-5641

BDS4 APPENDIX A - WARRANTY INFORMATION

A-1

APPENDIX A

WARRANTY INFORMATION

Industrial Drives, a Kollmorgen Division, warrantsthat equipment, delivered by it to the Purchaser, willbe of the kind and quality described in the salesagreement and/or catalog and that the equipment willbe free of defects in design, workmanship, andmaterial.

The terms and conditions of this Warranty areprovided with the product at the time of shipping orin advance upon request.

The items described in this manual are offered forsale at prices to be established by Industrial Drivesand its authorized dealers.

BDS4 APPENDIX B - MODEL NUMBERS

B-1

APPENDIX B

MODEL NUMBERS

Table B.1. PSR4/5 Model Number Scheme

EXAMPLE: PSR 4/5A- 2 50- XX* YY*

LEGEND: A B C D E F

LEGEND DEFINITION

A Power Supply with Regeneration (shunt regulation) and soft-start.

B Power Supply generation indicator.

4/5 Standard Configuration. Used with BDS4 series servo motor amplifiers.

4/5V Industrial Standard Configuration

4/5A U.L. 508 listed Configuration. Used with BDS4A series servo motor amplifiers.

C AC Line Voltage (L-L) RMS.

1 115 VAC, Single-Phase (not available for 50 and 75 amp models).

2 220 VAC, Single-Phase or 230 VAC, Three-Phase.

D 12,20,50,75 AC Line Current, RMS.

E Mechanical Options.

00 Standard - No Option (all models have side cover)

01 Use "00" for new applications (previously with side cover).

70 Custom.

71 Custom.

72 Custom.

73 Custom.

80 Custom.

91 Special (12 and 20 amp PSR4/5 units only, with cover, without connector kit, 2 axes maximum).

F Electrical Options.

00 Standard. No Options. 12 and 20 Amp models contain 40 Watt Internal Regeneration Resistor. 50and 75 Amp Models require Regeneration Resistor Kit EX-2X (must be ordered separately).

01 8.8 Ohms, 400 Watt External Regen, 230 Volt, 12 and 20 Amp Models Only. Requires ER-01External Resistor Kit.

02 5.5 Ohms, 200 Watt, 115 Volt External Regen, 12 and 20 Amp Models Only. Requires ER-02External Resistor Kit.

03 5.8 Ohms, 700 Watt, 230 Volt External Regen, 12 and 20 Amp Models Only. Requires ER-03External Resistor Kit.

20 Custom.

50 Without Soft-Start (50 and 75 Amp Models Only). Requires ER-2X External Resistor Kit.

70 Without Soft-Start and Regeneration (12 and 20 Amp Models Only).

80 Without Regeneration (12 and 20 Amp Models Only).

81 With 240 V logic supply unit, withou regen, with soft-start.

*XXYY - Omit when there are no options.

APPENDIX B - MODEL NUMBERS BDS4

B-2

Table B.2. ER-External Resistor Kit Model Number Scheme

EXAMPLE: ER- 01- XX

LEGEND: A B C

LEGEND DEFINITION

A External Resistor Kit for PSR4/5.

B Resistor Rating.

01 8.8 ohms, 400W, (12 or 20 amp, 230V models only).





22 2.2 ohms, 1000W, (75 amp, 230V models only).

23 2.2 ohms, 2000W, (75 amp, 230V models only).

C Options (None Available at this Printing).


B-3

Table B.3. BDS4 Model Number Scheme

EXAMPLE: BDS 4A- 2 03 H XX* YY* \ 204A Z

LEGEND: A B C D E F G H I

LEGEND DEFINITION

A Brushless Drive Sinewave Servo Amplifier.

B

VA

Amplifier generation indicator.Original Standard Configuration (no letter designation).Industrial Standard Configuration.U.L. 508 listed configuration.

C Maximum Output Voltage.1 115VAC (Nominal).2 230VAC (Nominal).

D 03, 06, 10, 20, 30, 40, 55 Output RMS Current Per Phase, Continuous.

E R/D Converter.H Standard. Accuracy 22 Arc Min. Maximum.J Special. Accuracy 8 Arc Min. Maximum. Required for 01, 02, 03 Electrical Options or

Motors with Nmax > 3 KRPM.

F Mechanical Options.00 Standard Unit. No Options.01 Side Cover Option.02 Custom.03 Custom.70 Custom.71 Custom.73 Custom.80 Custom.91 Side Cover Option w/ Cover, No Conn. Kit

G Electrical Options.00 Standard Unit. No Options.01 Electronic Encoder Output. Requires Type J R/D Converter.02 Electronic Encoder with Parallel Output. Requires Type J R/D Converter.03 Electronic Encoder with Parallel Output and Drive Signals Requires Type J R/D

Converter.05 Custom.06 Custom.07 Same as 01 Except Configured for LSB on Channel B. (Refer to Section E.2.2.1.)08 14-Bit R/D with 3500 RPM Tracking Rate. Requires Type J R/D09 Comp Card Without Components.10 Custom.11 Custom.12 Custom.13 Custom.14 Same as 01 Plus 08.15 Direction Limit Option Board.16 14-Bit R/D with 2000 RPM Tracking Rate. Requires Type J R/D Converter.


B-4

LEGEND DEFINITION

17 14-Bit R/D with 3500 RPM "J" Grade, W Direction Limit Option.18 Custom.19 16 Bit R/D 600 RPM "J" Grade R/D.81 Custom.83 Custom.84 Custom.85 Custom.91 Custom.92 Custom.93 Custom.94 Custom.95 Custom.96 12-Bit R/D 14k RPM "J" Grade with encoder equivalent option.

H Motor and Winding Designator.

I Compensation Designator.2 0 - 5 X Jm.3 5 - 20 X Jm.

ZZ Special.

*XXYY Omit when there are no options.

Table B.4. Compensation Card Model Designator

EXAMPLE: CMP- BDS4-203H 204A2

LEGEND: A B C

LEGEND DEFINITION

A Compensation Card.

B Amplifier Base Model Number.

C Motor, Winding, and Compensation Designator.

B.1 CABLE, BUS WIRE, AND MATING CONNECTOR KIT INFORMATION

Extra or spare bus wire and complete cable assemblies are available from Industrial Drives.

Mating connector kits are available from Industrial Drives or may be purchased directly from the connector vendor.

Table B.3. BDS4 Model Number Scheme (Continued)


B-5

B.2 CABLE MODEL NUMBER SCHEME FOR INDIVIDUAL CABLE SET

Motor cables are designed to provide reliable and cost-effective interconnection between Industrial Drives' GoldlineSeries Motors and any BDS Series Amplifier. GCS (Goldline Cable Set) models provide both motor (stator) andresolver (feedback) cable of equal length. Cables include motor mating plugs with various termination options at theamplifier end. There are 2 versions of the cable sets; the GCS and the GCSA. The GCS is used with motors thathave MS Bayonet-type connectors, while the GCSA is used with motors that have MS screw-type connectors. Toassist in ordering, the model number scheme for a cable set is as follows:

Table B.5. Cable Model Number Scheme for Individual Cable Set(Bayonet-Type Thread)

EXAMPLE: GCS - M6A / R - 4/5 - 03

LEGEND: A B C D E

LEGEND DEFINITION

A Goldline Cable Set. Consists of one motor stator and one feedback cable withBayonet type thread.

B Motor Power Cable with mating plug for particular frame size.

M6A B-60X-X-AX & BX Motors (up to 40 amps continuous).

M6B B-60X-X-AX & BX Motors (up to 65 amps continuous).



C Motor Feedback/Option Cable with Mating Plug.

R System Resolver Only.

RBT System Resolver, Brake, Tachometer.

D Amplifier Termination.

4/5 BDS4 or BDS5, 3-20 Amp Models.

4/5H BDS4 or BDS5, 30-55 Amp Models.

N Not Terminated.

E Cable Length to Motor. 3 to 75 Meters in 3-Meter Increments.


B-6

Table B.6. Cable Model Number Scheme for Individual Cable Set(Screw-Type Thread)

EXAMPLE: GCSA - M4 / R - 4/5 - 03

LEGEND: A B C D E

LEGEND DEFINITION

A Goldline Cable Set. Consists of one motor stator and one feedback cable with screw-type thread.

B Motor Power Cable with mating plug for particular frame size.






C Motor Feedback/Option Cable with Mating Plug.



D Amplifier Termination.

4/5 BDS4 or BDS5, 3-20 Amp Models.

4/5H BDS4 or BDS5, 30-55 Amp Models.

N Not Terminated.

E Cable Length to Motor. 3 to 75 Meters in 3-Meter Increments.


B-7

B.3. CABLE MODEL NUMBER SCHEME FOR INDIVIDUAL CABLE

Individual cables can be provided by GC (Goldline Cable) Models. To assist in ordering, the model number schemefor an individual cable is as follows:

Table B.7. Cable Model Number Scheme for Individual Cable(Bayonet-Type Connector)

EXAMPLE: GC - M2 - 4/5 - 03

LEGEND: A B C D

LEGEND DEFINITION

A Goldline Cable With Bayonet-Type Connector (individual cable).

B Motor Power Cable with Mating Plug or Feedback/Option Cable.

M1 B-10X Motors.

M2 B-20X Motors.

M4 B-40X Motors.







AR Application Resolver.

C Amplifier Termination.

4/5 BDS4 or BDS5, 3-20A Models.

4/5H BDS4 or BDS5, High Current Models.

N Not Terminated.

D Cable Length to Motor. 3 to 75 Meters in 3-Meter Increments.


B-8

Table B.8. Cable Model Number Scheme for Individual Cable(Screw-Type Connector)

EXAMPLE: GCA - M4 - 4/5 - 03

LEGEND: A B C D

LEGEND DEFINITION

A Goldline Cable with screw-type connector (individual cable).

B Motor Power Cable with Mating Plug or Feedback/Option Cable.

M4 B-40X Motors (up to 40 amps continuous).

M6A B-60X Motors (up to 40 amps continuous).

M6B B-60X Motors (up to 65 amps continuous).

M8A B-80X Motors (up to 65 amps continuous).

M8B B-80X Motors (up to 115 amps continuous).



AR Application Resolver.

C Amplifier Termination.

4/5 BDS4 or BDS5, 3 to 20 A Models.

4/5H BDS4 or BDS5, High Current Models.

N Not Terminated.

D Cable Length to Motor. 3 to 75 Meters in 3-Meter Increments.


B-9

B.4 SPECIAL CABLES FOR RESOLVER FEEDBACK AND INTERFACE

The GC specials are designed to eliminate the need for the customer to make crimp connections for BDS4input/output connector (C1) and BDS4 resolver connector (C2). These cables are terminated at C1 and C2 on theBDS4 and are unterminated at the opposite end. The unterminated end is intended to be connected into a customer-supplied terminal block. To assist in ordering, the model number schemes for these special cables are as follows:

Table B.9. Resolver Feedback Cables

GC-RF-4/5-XX Resolver feedback flying lead cable (not terminated at the motor). XX-length in3 meter increments; 03, 09, etc.

GC-IOF-4-XX I/O flying lead cable (not terminated at customer's interface). XX-length in 3meter increments; 03, 09, etc.

B.5 SPECIAL CABLES FOR LOGIC POWER SUPPLY

Special logic power supply cables are available to accommodate the various physical sizes of BDS4 and PSR4/5modules and are designed based on standard module spacing requirements. Refer to drawing B-84929 forinformation concerning decoding the model numbers of special logic bus cables. To assist in ordering, the modelnumber scheme for this cable is:

GC-LOGIC-XXXXXXX

BDS4 APPENDIX C - CONNECTOR KITS & TOOLS

C-1

APPENDIX C

CONNECTOR KITS & TOOLS

C.1 INTRODUCTION

Mating connectors are customer furnished items which may be ordered either from Industrial Drives or purchaseddirectly from the connector vendor. Ordering information is as follows:

Table C.1. Connector Kit BDS4C-100

INDUSTRIAL DRIVES CONNECTOR KIT -- PART NUMBER----BDS4C-100

BDS4 - 3, 6 and 10 AMP MODELS

CONNECTOR DESCRIPTION MOLEX PART NO. I.D. PART NO.

C1 Connector Housing, 20Position Female

39-01-2205 A-83908-020

C2 Connector Housing, 12Position Female

39-01-2125 A-83908-012

C3 Connector Housing,8 Position Female

39-01-2085 A-83908-008

C1, C2, C3 PIN, Female,(18-24 AWG)

39-00-0039 A-83909-002

APPENDIX C - CONNECTOR KITS & TOOLS BDS4

C-2



BDS4 - 20 AMP MODELS



39-01-2205 A-83908-020


39-01-2125 A-83908-012


39-01-2085 A-83908-008

C4 Connector Housing,4 Position Male

39-01-2045 A-83908-004

C1, C2, C3, C4 PIN, Female,(18-24 AWG)

39-00-0039 A-83909-002



BDS4 - 30, 40, and 55 AMP MODELS



39-01-2205 A-83908-020


39-01-2125 A-83908-012


39-01-2085 A-83908-008

C4 Connector Housing,4 Position Male

39-01-2045 A-83908-004

C1, C2, C3, C4 PIN, Female,(18-24 AWG)

39-00-0039 A-93105-002

BDS4 APPENDIX C - CONNECTOR KITS & TOOLS

C-3

Table C.4. Connector Kit PSR4/5C-200

INDUSTRIAL DRIVES CONNECTOR KIT -- PART NUMBER----PSR4/5C-200

PSR4/5 - 12, 20, 50 and 75 AMP MODELS



39-01-2065 A-83908-006


39-01-2085 A-83908-008

C1, C2 PIN, Female(18-24 AWG)

39-00-0039 A-83909-002

Table C.5. Connector Tools

CONNECTOR TOOLS (PINS, MINI FIT JR.) FROM MOLEX

Description EngineeringNumber

OrderNumber

Hand Crimping Tool HTR-60622 11-01-0197

Extractor Tool HT-60630A 11-03-0038

MOLEX TELEPHONE NUMBER: (708) 969-4550

BDS4 APPENDIX D - SPECIFICATIONS

D-1

APPENDIX D

SPECIFICATIONS

D.1 INTRODUCTION

The Specifications for the PSR4/5 and BDS4 areprovided in this appendix. Derating information isalso included for environments with high ambient

temperatures. As a general rule, the failure rate ofsolid state components doubles for every ten degreesCelsius rise in temperature. This exponential failurerate is strong incentive for lower ambienttemperatures.

APPENDIX D - SPECIFICATIONS BDS4

D-2

Table D.1. PSR4/5 Specifications

DESCRIPTION PSR4/5-112 PSR4/5-120

Main AC Line Input Voltage 90 - 160 VAC 90 - 160 VAC

Phase 1 Phase 1 Phase

Frequency 47 - 63 HZ 47 - 63 HZ

Current RMS/Phase, Continuous 12 AMPS 20 AMPS

Current RMS/Phase, Peak (2 Sec.) 24 AMPS 40 AMPS

Current RMS/Phase, Peak (50 msec.) 50 AMPS 80 AMPS

Control AC Line Input Voltage 95 - 132 VAC 95 - 132 VAC



Current RMS 1.5 AMPS 1.5 AMPS

Output Power 1.0 K WATTS 1.7 K WATTS

Volts 140 VDC 140 VDC

Unregulated Logic Bus Output

No Load ± 26 VDC MAX+ 14 VDC MAX

Full Load ± 14.5 VDC MIN. @ 1 AMPS+ 6.5 VDC MIN. @ 2 AMPS

Internal Shunt Regulator, Peak Current 30 A 30 A

Internal Shunt Regulator, Resistance 7.5 OHM 7.5 OHM

Internal Shunt Regulator, Resistor Power 40 WATTS 40 WATTS

External Shunt Regulator, Peak Current 50 A 50 A

External Shunt Regulator, Min. Resistance 5.5 OHM 5.5 OHM

External Shunt Regulator, Resistor Power Model Dependant Model Dependant

Internal Power Dissipation, Continuous (Less Shunt Regulator)

60 W 90 W

Soft-Start Surge Current (MAX) 35 AMPS 35 AMPS

Soft-Start Charge Time (MAX) 0.25 SEC. 0.25 SEC.


D-3

Table D.1. PSR4/5 Specifications (Con't)












Output Power 3.6 K WATTS 6.0 K WATTS


Unregulated Logic Bus OutputNo Load ± 26 VDC MAX

+ 14 VDC MAX

Full Load ± 14.5 VDC MIN. @ 1 AMPS+ 6.5 VDC MIN. @ 2 AMP

Internal Shunt Regulator, Peak Current 32 A 32 A

Internal Shunt Regulator, Resistance 12.5 OHM 12.5 OHM

Internal Shunt Regulator, Resistor Power 40 WATTS 40 WATTS

External Shunt Regulator, Peak Current * 50 A 50 A

External Shunt Regulator, Min. Resistance * 8.8 OHMS 8.8 OHMS

External Shunt Regulator, Resistor Power Model Dependant Model Dependant


60 W 90 W



* The -XX03 Electrical Option version has a peak regulator current of 75 amps, a minimum resistanceof 5.8 ohms, and a power rating of 700 watts.


D-4

Table D.1. PSR4/5 Specifications (Con't)












Output Power 15 K WATTS 22.5 K WATTS


Unregulated Logic Bus OutputNo Load ± 26 VDC MAX

+ 14 VDC MAX

Full Load ± 14.5 VDC MIN. @ 2 AMPS+ 6.5 VDC MIN. @ 4 AMPS

Shunt Regulator, Peak Current 100 A 200 A

Shunt Regulator, Min. Resistance 4.3 OHM 2.15 OHM


175 W 250 W

Internal Power Dissipation, Peak (2 SEC.) 325 W 475 W




D-5

Table D.2. BDS4 Specifications

DESCRIPTION BDS4-103X BDS4-106X BDS4-110X BDS4-120X

MAIN DC BUS Minimum Maximum

125 VDC 225 VDC

125 VDC 225 VDC

125 VDC 225 VDC

125 VDC 225 VDC

Unregulated Logic Bus Input

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

Fan AC Line Input --- --- --- 95-132 VAC 50/60 HZ @ 0.5AMPS

Output Current (RMS/PHASE) Convection Cooled (45° C AMB) Continuous (RMS) Peak (2.0 SEC.) (RMS)

3.0 AMPS 6.0 AMPS

6.0 AMPS 12.0 AMPS

10.0 AMPS 20.0 AMPS

(Fan Cooled) 20.0 AMPS 40.0 AMPS

Output KVA (@ 160 VDC BUS) Continuous (45°C AMB) Peak (2.0 SEC.)

0.5 KVA

1.0 KVA

1.0 KVA

2.0 KVA

1.7 KVA

3.3 KVA

3.3 KVA

6.7 KVA

Internal Heat Dissipation

30 WATTS 50 WATTS 75 WATTS 135 WATTS

PWM Switching Frequency

10.0 KHZ 10.0 KHZ 10.0 KHZ 10.0 KHZ

Motor Current Ripple Frequency ± 10%

20.0 KHZ 20.0 KHZ 20.0 KHZ 20.0 KHZ

Resolver Excitation Frequency

7.0 KHZ 7.0 KHZ 7.0 KHZ 7.0 KHZ

Form Factor RMS/AVG ≤ 1.01 ≤ 1.01 ≤ 1.01 ≤ 1.01

Speed Regulation (Long Term)

0.075%/°C 0.075%/°C 0.075%/°C 0.075%/°C

†Minimum Controllable Speed:

Standard 12-Bit R/D With 8000 RPM Max. Tracking Rate

12-Bit R/D With 14000 RPM Max. Tracking Rate




2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

† Minimum controlled speed is defined as the minimum speed that can readily be run. The standard BDS4 is configured with a12-bit R/D converter for a maximum motor speed of 8,000 RPM. Other resolutions and maximum motor speeds (trackingrates) must be ordered as specials.


D-6

Table D.2. BDS4 Specifications (Con't)

DESCRIPTION BDS4-203X BDS4-206X BDS4-210X BDS4-220X


250 VDC360 VDC

250 VDC 360 VDC

250 VDC 360 VDC

250 VDC 360 VDC

Unregulated Logic Bus Input

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

Fan AC Line Input --- --- --- 95-132 VAC 50/60 HZ @ 0.5AMPS

Output Current (RMS/PHASE) Convection Cooled (45° C AMB) Continuous (RMS) Peak (2.0 SEC.) (RMS)

3.0 AMPS 6.0 AMPS

6.0 AMPS 12.0 AMPS

10.0 AMPS 20.0 AMPS

(Fan Cooled) 20.0 AMPS 40.0 AMPS

Output KVA (@330 VDC BUS) Continuous (45°C AMB) Peak (2.0 SEC.)

1.1 KVA

2.2 KVA

2.2 KVA

4.4 KVA

3.6 KVA

7.3 KVA

7.3 KVA

14.5 KVA

Internal Heat Dissipation

40 WATTS 65 WATTS 95 WATTS 175 WATTS

PWM Switching Frequency

10.0 KHZ 10.0 KHZ 10.0 KHZ 10.0 KHZ


20.0 KHZ 20.0 KHZ 20.0 KHZ 20.0 KHZ

Resolver Excitation Frequency

7.0 KHZ 7.0 KHZ 7.0 KHZ 7.0 KHZ

Form Factor RMS/AVG ≤ 1.01 ≤ 1.01 ≤ 1.01 ≤ 1.01


0.075%/°C 0.075%/°C 0.075%/°C 0.075%/°C







2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM


D-7

DESCRIPTION BDS4-230X BDS4-240X BDS4-255X


250 VDC 360 VDC

250 VDC 360 VDC

250 VDC 360 VDC

Unregulated Logic Bus Input ± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

± 14.5-26 VDC @ 0.25 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

+ 6.5-14 VDC @ 0.50 AMPS

Fan AC Line Input 95 - 132 VAC @ 0.5 AMPS

95 - 132 VAC @ 0.5 AMPS

95 - 132 VAC @ 0.75 AMPS

Output Current (RMS/PHASE) (45° C AMB) Continuous (RMS) Peak (2.0 SEC.)

(FAN COOLED) 30 AMPS 60 AMPS

(FAN COOLED) 40 AMPS 80 AMPS

(FAN COOLED) 55.0 AMPS 110 AMPS

Output KVA (@ 330 VDC BUS) Continuous (45°C AMB) Peak (2.0 SEC.)

11.0 KVA 22.0 KVA

14.5 KVA 29 KVA

20 KVA 40 KVA

Internal Heat Dissipation 255 WATTS 335 WATTS 445 WATTS

PWM Switching Frequency 10.0 KHZ 10.0 KHZ 10.0 KHZ


20.0 KHZ 20.0 KHZ 20.0 KHZ

Resolver Excitation Frequency 7.0 KHZ 7.0 KHZ 7.0 KHZ

Form Factor RMS/AVG ≤ 1.01 ≤ 1.01 ≤ 1.01


0.075%/°C 0.075%/°C 0.075%/°C







2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

2.0 RPM

3.5 RPM

1/8 RPM

1/4 RPM

1/64 RPM

† Minimum controlled speed is defined as the minimum speed that can readily be run. The standard BDS4 isconfigured with a 12-bit R/D converter for a maximum motor speed of 8,000 RPM. Other resolutions and maximummotor speeds (tracking rates) must be ordered as specials.

Table D.2. BDS4 Specifications (Con't)


D-8

Table D.3. Derating Data

Derating Information (Continuous Duty)

BDS460HZ

Derating @55° C*50HZ Operation In45° Max. Ambient

50HZ % Total Derating @ 55oC

3 A 20% No Derating 20%




30 A 20% 20% 36%

40 A 20% 20% 36%

55 A 20% 20% 36%

PSR4/5Logic Bus Supply

60HZDerating @55° C*

50HZ Operation In45° Max. Ambient


12A 10% No Derating 10%




PSR4/5Main Bus Supply

60HZDerating @55° C*

50HZ Operation In45° Max. Ambient


12A No Derating 20% 20%

20A No Derating 20% 20%

50A 10% 10% 20%

75A 10% 10% 20%

* Based on Derating of 2% /°°°° C from 45°°°° C to 55°°°° C.Consult Factory for Derating Above 55°°°° C.


D-9

Table D.4. Environmental Specifications

Operating Temperature 0o C to 45o C

Storage Temperature -20o C to 70o C

Humidity (Non-Condensing) 10% to 90%

Table D.5. Mechanical Specifications

WIDTH HEIGHT DEPTH WEIGHT

MODELNUMBER

MM IN. MM IN. MM IN. Kg(f) LB.

BDS4-X03X- 60 2.3 340 13.5 280 11 2.95 6 1/2

BDS4-X06X- 60 2.3 340 13.5 280 11 3.40 7 1/2

BDS4-X10X- 88 3.5 340 13.5 280 11 6.01 13 1/4

BDS4-X20X- 106 4.2 340 13.5 280 11 6.35 14

BDS4-230X- 140 5.5 340 13.5 284 11.2 9.75 21 1/2

BDS4-240X- 140 5.5 340 13.5 284 11.2 9.98 22

BDS4-255X- 160 6.3 340 13.5 284 11.2 10.43 23

PSR4/5-X12- 80 3.1 340 13.5 280 11 4.76 10 1/2

PSR4/5-X20- 80 3.1 340 13.5 280 11 5.44 12

PSR4/5-X50- 140 5.5 340 13.5 284 11.2 12.02 26 1/2

PSR4/5-X75- 140 5.5 340 13.5 284 11.2 12.25 27

BDS4 APPENDIX E - OPTIONS

E-1

APPENDIX E

OPTIONS

Options are brought into existence from time to timeto satisfy specific needs and to add versatility to theproduct. (Refer to the Model Number Schemes inAppendix B.)

The BDS4 and PSR4/5 may be ordered with variousmechanical and electrical options, standard orcustom designed for particular applications. If afeature is desired which is not covered here, consultthe Industrial Drives Sales Staff for information oncustom designed options.

E.1 PSR4/5A/V ELECTRICALOPTIONS

12 and 20 AMP Models:

OPTION:

-01 400 watts external regeneration resistor kitfor 230V systems (refer to Section 4.7).



-80 without Regen or dynamic brake

-81 with 240 V logic supply, without Regen ordynamic brake

50 and 75 AMP Models:

OPTION:

-20 with undervolt fault

-50 without soft-start circuitry.

E.2 BDS4 ELECTRICAL OPTIONS

The standard BDS4 servo amplifier is fitted with a12-bit R/D converter which allows a maximumtracking rate of 8000 RPM and a maximum operatingspeed of 7500 RPM.

The BDS4 amplifiers are available with standardoptions which are discussed in the following sections.These options are either integrated into the maincircuit board of the BDS4 amplifier or appear asOption Boards that are mounted inside of the BDS4chassis.

E.2.1 Integrated Options

R/D Converter Resolution and Tracking RateOptions:

Optional R/D resolutions and tracking rates areavailable and produce higher resolution positioninformation and/or better low-speed performance.These options are integrated into the main circuitboard (motor control board) within the BDS4amplifier and are as follows:

Option - 08 contains a 14-bit R/D, produces amaximum tracking rate of 3500 RPM, and amaximum operating speed of 3200 RPM.

Option - 11 contains a 16-bit R/D, produces amaximum tracking rate of 500 RPM, and a maximumoperating speed of 450 RPM.

Option - 16 contains a 14-bit R/D, produces amaximum tracking rate of 2000 RPM, and amaximum operating speed of 1800 RPM.

Accuracies, repeatability, and resolutionspecifications are recorded in the tables located inSection E.2.2.4.

APPENDIX E - OPTIONS BDS4

E-2

E.2.2 BDS4-OPT2/3A Option Board

The option board can support 10-, 12- 14-, or 16-bitR/D converters (mounted within the BDS4). Thecard may be configured one of three ways:

01- as a differential quadrature encoder interfacewith marker pulse.

02- as a 12- to 16-bit buffered parallel resolverdata interface.

03- as a 12- to 16-bit buffered parallel resolverdata interface with drive control signals.

E.2.2.1 BDS4-OPT2/3A-01 BOARDElectronic Encoder Output

When configured as a BDS4-OPT2/3A-01 board,only the encoder outputs are offered. The boardfunctions only to convert the binary (motor shaft)position information from the R/D (Resolver-to-Digital) converter, located within the BDS4 amplifier,to differential quadrature encoder signals with markerpulse.

The output interface connections are made viaConnector 32, mounted on the BDS4-OPT2/3A-01Board. This connector is an 8-Pin Molex MINI-FITJR connector and is located just to the left ofConnector C1 mounted in the top front of the BDS4amplifier .

The pin outs are as follows:

OUT A 5 1______OUT A

OUT B 6 2______OUT B

OUT Z 7 3______OUT Z

COM 8 4 COM

Figure E.1. Connector 32

The encoder interface option provides a differentialquadrature synthesized encoder output and a

differential marker pulse output for customer use.Each output pair (OUT A or A phase, OUT B or Bphase, and OUT Z or Z phase) is driven by aDS8830/SN75183 differential line driver integratedcircuit. The voltage levels transition between + 5volts and common. This interface is capable ofsinking and sourcing 40 milliamps of current. Thedifferential outputs are designed to drive long lengthsof coaxial cable, strip line, or twisted pairtransmission lines with characteristic impedances of50 to 500 ohms.

The quadrature signal is generated by the followingsequence:

Refer to Drawing D-93179-1.

Up to sixteen parallel resolver data bits are brought tothe BDS4-OPT2/3A Option Board via connectors 7and 33. These bits first pass through LS244 databuffers. Next the data bits are routed to a double rowjumper/header (component 35). At this header thequadrature resolution is selected by manipulating twojumpers. The resolution can be from 16 to 16384encoder lines in increments of power of two (2x) (i.e.,16, 32, 64, 128, 256, 512, 1024, 2048, 4096, 8192,16384). The following jumper table shows thejumper combinations for the resolutions available.After two of the twelve data bits have been selected atthe jumper/header block (Component 35) by the twojumper selections, these two signals are routed to apair of Exclusive-Or gates. This is where thequadrature (A Phase offset from B Phase by 90degrees) signal pair are generated.

After this the two quadrature signals are latched by apair of LS175 flip-flops. The non-inverting outputfrom each flip-flop drives an LED. The invertingoutput from each flip-flop drives a pair of DS8830 or75183 line drivers. The line driver outputs routestraight across a jumper/header strip (this is used withother options) and terminate at customer Connector32.

The marker pulse signal is generated by the followingsequence:

All sixteen parallel resolver data bits are brought tothe BDS4-OPT2/3A Option Board. These bits firstpass through LS244 data buffers. Next the data bitsare routed to a bank of DIP switches consisting ofComponents 23 and 26. At these switches the markerpulse width is selected. For a minimum pulse widthall switches should be closed. As more switches are


E-3

opened from the LSB to the MSB, the pulse widthwill become wider. The marker pulse width selectedhas no effect on the quadrature resolution selectedalthough these two types of signals are normallyrelated on a standard encoder. The jumper/switchtable that follows shows the wide and narrow markerpulse selection with each of the eleven encoderequivalent resolutions available. After the dip switch,the selected signals are Anded together then Andedwith all of the MSB data lines that were not switch-selectable. Note that the combination of the twoNand gates feeding into an Or gate results in theequivalent of a large Nand gate. The output of the Orgate feeds into a LS175 flip-flop. The non-invertingoutput of the flip-flop drives an LED. The invertingoutput of the flip-flop drives a DS8830 or 75183 linedriver. The line driver outputs route straight across ajumper/header strip (this is used with other options)and terminate at customer Connector 32.

The encoder resolution (OUT A and OUT B) can bejumpered for resolutions between 16 to 16384 lines inbinary (2x) increments. The OUT Z (Marker Pulse)can be switch-selected for either a narrow pulse widthor a wide pulse width in relation to the particularresolution selected. Note that any other marker pulsewidth can be selected as it has no direct effect on theselected resolution of the encoder equivalent signal.

STANDARD 12-BIT CONFIGURATION

Place two jumpers on header #35:

JUMPER PINS I-JJUMPER PINS K-L

Adjust the Dip Switch #23 & #36 to:

SWITCH A - OFFSWITCH B - OFFSWITCH C - OFFSWITCH D - OFFSWITCH E - OFFSWITCH F - ONSWITCH G - ONSWITCH H - ONSWITCH I - ONSWITCH J - ONSWITCH K - ONSWITCH L - ON

Double Row Header #28:

JUMPER 1-2

JUMPER 3-4JUMPER 5-6JUMPER 7-8JUMPER 9-10JUMPER 11-12

See Schematic Drawing D-93179

E.2.2.2 BDS4-OPT2/3A-02 BOARDElectronic Encoder with Parallel Output (WithoutDrive Signals)

The parallel resolver data option provides 12 - 16 bitsof buffered resolver data output. The signals areoutput on one 34-pin ribbon cable connector. Themating connector for the ribbon cable connector is aBerg P/N 66900-234 or equivalent. The ribbon cablepinouts are listed in Table E.2 and on drawingC-93185.

NOTE

POSOO-POS15 are sequencedto agree with PMC-960

positioner board signal namesfor a 12-bit configuration. Due

to this, POS12-POS15 willappear to be out of sequence.

E.2.2.3 BDS4-OPT2/3A-03 BOARDElectronic Encoder with Parallel Output (With DriveSignals)

This option is similar to that discussed in SectionE.2.2.2 with the exception that it also provides for ameans by which the Industrial Drives' 960 positioncontroller can interface directly with the BDS4 motorcontroller. This is accomplished by adding a smallcable between Connector 32 on the BDS4 OPT2/3Aboard and Connector C1 of the BDS4 amplifier. TheBDS4 motor controller signals are identified in theabove table by the addition of an asterisk by the pinnumbers. Connector 37 on the BDS4-OPT2/3Aboard is located just to the left of Connector C1mounted in the top front of the BDS4.

E.2.2.4 BDS4 AND BDS4-OPT2/3A(BOARD) SYSTEM SPECIFICATIONSAccuracies, repeatability, and resolutionspecifications are recorded in Table E.3.


E-4

E.3 BDS4-OPT-D/L OPTION BOARD

• Function:

The BDS4-OPT-D/L option board functions as aninterface module between the BDS4 and machinetravel limit switches. There are separate inputs forthe CW and CCW directions of motor shaft rotation(viewing the motor from the output shaft end). In theevent a machine limit switch is activated, the motorwill decelerate (at maximum rate) to zero speed andremain against the "stop" in a reduced current mode.The BDS4 will remain fully operational with fullcurrent and torque available for movement in theopposite direction (provided the opposite limit switchis not activated).

• Wiring

Reference to Drawing A-93541 will assist in wiringthe D/L option board. The speed command (positionerror) to the BDS4 amplifier must be wired to 1 and 4of the special differential input terminals on the D/Loption board, NOT TO THE STANDARD INPUTOF THE BDS4. In order to initiate restrictedmovement the customer must provide 5 to 28 VDC,through limit switches on the machine, to the CW andCCW inputs of the D/L option board. The 5 to 28VDC supply must be capable of sourcing 20 ma ofcurrent.

• Board Configuration:

The D/L option board is shipped from the factoryconfigured so that the absence of input (5 to 28 VDC)from either of its CW or CCW inputs activate thedirection limit mode. If it is desired that directionlimit be activated by the presence of voltage, removeJumper 26 located between Pins 2 and 3 on the boardand install it between Pins 1 and 2.

• Direction Limit Indication:

When the Direction Limit mode is activated, a redLED will become illuminated. The LED is locatedjust behind option board Connector 3 and can be seenthrough the opening in the front of the BDS4.

• Adjustments:

There is only one adjustment on the D/L optionboard. It is the Command Scale Pot, and is locatednext to option board Connector 67.

Perform the adjustment procedure in the followingmanner:

1. Adjust the Command Scale pot in the front ofthe BDS4 fully CCW.

2. Adjust the Command Scale pot on the D/Loption board in the standard manner byreferring to Section 4.4.1.3 or 4.4.1.4 of thismanual.


E-5

Table E.1. BDS4-OPT2/3A-01 Board Specifications

ENCODER RESOLUTIONSELECTION MARKER PULSE WIDTH

ENCODERRESOLUTION

OUT A & OUT BJUMPER/HEADER

#35DIP SWITCH #23 & #36

(0 = OFF 1 = ON)

EncoderQuad

EncoderLines JUMPER JUMPER WIDE MARKER* NARROW MARKER

Counts (/rev) #1 #2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

65536** 16384 A - B C - D 0 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1

32768** 8192 C - E D - F 0 0 1 1 1 1 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1

16384** 4096 E - F G - H 0 0 0 1 1 1 1 1 1 1 1 1 0 0 0 1 1 1 1 1 1 1 1 1

8192** 2048 G - I H - J 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1

4096* 1024* I -J* K -L* 0 0 0 0 0 1 1 1 1 1 1 1* 0 0 0 0 0 1 1 1 1 1 1 1

2048 512 K - M L - N 0 0 0 0 0 0 1 1 1 1 1 1 0 0 0 0 0 0 1 1 1 1 1 1

1024 256 M - N O - P 0 0 0 0 0 0 0 1 1 1 1 1 0 0 0 0 0 0 0 1 1 1 1 1

512 128 O - Q P - R 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1

256 64 Q - R S - T 0 0 0 0 0 0 0 0 0 1 1 1 0 0 0 0 0 0 0 0 0 1 1 1

128 32 S - U T - V 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 1 1

64 16 U - V W - X 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 1 1

* This is the standard setting (12-bit).

** These resolutions are not available on all BDS4 models. A high resolution R/D is also required with theseresolutions.


E-6

Table E.2. OPT2/3A-02 and OPT2/3A-03 Pinouts

CONNECTOR #4

*1 ICMD DIFF HI (current/velocity command) (analog)

*2 ACOM DIFF LOW (connected to analog common)

*3 TACH TACH HI (analog signal)

*4 ACOM TACH LOW (connected to analog common)

5 ALOCK ANALOG LOCK HI (analog signal)

6 ACOM ANALOG LOCK LOW (analog common)

*7 DRVENB' Servo Drive Enable (active low)

8 DCOM Digital Common

*9 DRVRDY' Servo Drive Ready (active low)


11 BUSY Resolver's R-to-D Converter Busy (active high)


13 N/C Reserved


15 POSOO Least Significant Bit for 12-Bit R/D


17 POSO1 Next to Least Significant Bit for 12-Bit R/D


19 POSO2 One Input Bit of Resolver








27 POS10 Next to Most Significant Bit of the Resolver

28 POS11 Most Significant Bit of the Resolver

29 POS12** Next to Least Significant Bit for 14-Bit R/D

30 POS13** Least Significant Bit for 14-Bit R/D

31 POS14** Next to Least Significant Bit for 16-Bit R/D

32 POS15** Least Significant Bit for 16-Bit R/D

33 N/C Reserved

34 SHIELD EMI Isolated Shield Common

* These signals are only available on the OPT2/3A-03 option.

** These signals are not available on all models of the BDS4.


E-7

Table E.3. System Specifications

ACCURACIES J GRADE R/D H GRADE R/D

R/D CONVERTER ACCY ± 4.0 ARC MIN ± 22.0 ARC MIN

RESOLVER ACCY ± 7.0 ARC MIN ± 7.0 ARC MIN

RESOLVER MOUNTING ± 3.0 ARC MIN ± 3.0 ARC MIN

UNCERTAINTY**(± 1 Count) ± 5.27 ARC MIN ± 5.27 ARC MIN

WORST CASE ACCY* 19.27 ARC MIN 37.27 ARC MIN

0.32 DEGREES 0.62 DEGREES

± 1.8 BITS ± 3.5 BITS

TYPICAL ACCY 13.87 ARC MIN 28.55 ARC MIN


± 1.3 BITS ± 2.5 BITS

REPEATABILITY 5.27 ARC MIN 5.27 ARC MIN


1.0 BIT 1.0 BIT

RESOLUTION 212 BITS (4096) 212 BITS (4096)

* Worst Case Analysis assumes all errors add together.

** For 12-bit systems only. For 14-bit systems, the uncertainty drops to ± 1.32 arc min and for 16-bit systems,the uncertainty drops to ± 0.33 arc min. Therefore, the worst case and typical accuracies will be reducedslightly for 14- and 16-bit systems.


E-8

Table E.4. R/D Converter Speeds

R/D CONVERTER MAXIMUM SPEEDMAXIMUM

R/D RESOLUTION TRACKING RATE OPERATING SPEED

12-Bit 233.33 RPS 8000 RPM 7500

12-Bit 133.33 RPS 8000 RPM 7500

14-Bit 58.33 RPS 3500 RPM 3150

14-Bit 33.33 RPS 2000 RPM 1800

16-Bit 15.0 RPS 900 RPM 800

16-Bit 13.33 RPS 500 RPM 450


E-9

Figure E.2. Encoder Output Timing

F-1

APPENDIX F

DRAWINGS

DRAWING

A-63542……….. Motor ConnectionA-83908……….. Purchase Spec. for Mini-Fit, Jr.Series ConnectorA-83909……….. Purchase Spec. for Mini-Fit, Jr.Series TerminalsA-84385……….. Outline & Dimension PSR4/5 - 12 & 20 AmpA-93031……….. Outline & Dimension PSR4/5 - 50 & 75 AmpA-93092……….. PRS4/5 50A / 75A (with & without Soft Start) Simplified SchematicA-93112……….. Outline & Dimension BDS4 - 55 AmpA-93141……….. Wiring & Mounting DiagramER-20A-93156……….. Outline & Dimension BDS4 - 30 & 40 AmpA-93231……….. BDS4 Wiring DiagramA-93314……….. Wiring & Mounting Diagram ER-21A-93315……….. Wiring & Mounting Diagram ER-22A-93316……….. Wiring & Mounting Diagram ER-23A-93369……….. GOLDLINE Amplifier Assembly Guide for Resolver CablesA-93408……….. PRS4/5 12A / 20A Simplified SchematicA-93409……….. PSR4/5 Internal SchematicA-93414……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (30, 40, & 55 Amp)A-93421……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (3 thru 20 Amp)A-93538……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (3 thru 20 Amp)A-93539……….. GOLDLINE Amplifier Assembly Guide for Motor Cables (30, 40, & 55 Amp)A-93540……….. GOLDLINE Amplifier Assembly Guide for Resolver CablesA-93541……….. BDS4 Direction Limit Wiring DiagramA-93567……….. Outline & Dimension BDS4 - 3 & 6 AmpA-93568……….. Outline & Dimension BDS4 - 20 AmpA-93572……….. Outline and Dimension BDS4 - 10 AmpA-93656……….. Mounting Hole Pattern BDS4, BDS5, PSR4/5A-93700……….. DC Bus Cable Assembly for BDS4/5 & PSR4/5A-93703……….. Mounting Hole Pattern BDS4B-84929……….. BDS4 & BDS5 Logic Cable AssemblyC-84113……….. BDS4 Simplified SchematicC-84723……….. PSR4/5 Simplified SchematicC-84724……….. PSR4/5 Internal SchematicC-93185.……….BDS4 - OPT2/3A Pinout OptionsD-93179……….. BDS4 - OPT2/3A

BDS4 GLOSSARY

G-1

GLOSSARY

Acceleration

The change in velocity as a function of time.Acceleration usually refers to increasing velocity anddeceleration describes decreasing velocity.

Ambient Temperature

The temperature of the cooling medium, usually air,immediately surrounding the motor or another device.

Amplifier

Electronics which convert low level command signalsto high power voltages and currents to operate a servomotor.

Brushless Servo Drive

A servo drive used to control a permanent magnetsynchronous AC motor. May also be referred to as anAC Servo Drive.

Drive

This is the electronics portion of the system thatcontrols power to the motor.

Drive, Analog

Usually referring to any type of motor drive in whichthe input is an analog signal.

Drive, Servo

A motor drive which utilizes internal feedback loopsfor accurate control of motor current and/or velocity.

Efficiency

The ratio of output power to input power.

Encoder, Absolute

A digital position transducer in which the output isrepresentative of the absolute position of the inputshaft within one (or more) revolutions. Output isusually a parallel digital word.

Encoder, Incremental

A position encoding device in which the outputrepresents incremental changes in position.

Encoder, Marker

A once-per-revolution signal provided by someincremental encoders to specify a reference pointwithin that revolution. Also known as ZeroReference signal or index pulse.

Encoder Resolution

A measure of the smallest positional change whichcan be detected by the encoder.

Feedback

A signal which is transferred from the output back tothe input for use in a closed loop system.

Following Error

The position error during motion resulting from useof a position control loop with proportional gain only.

Friction

A resistance to motion caused by surfaces rubbingtogether. Friction can be constant with varying speed(coulomb friction) or proportional to speed (viscousfriction) or present at rest (static friction).

Full Load Current

The armature current of a motor operated at its fullload torque and speed with rated voltage applied.

Full Load Speed

The speed of a motor operated with rated voltage andfull load torque.

Gain

The ratio of system output signal to system inputsignal. The control loop parameter that determinessystem performance characteristics.

GLOSSARY BDS4

G-2

HP: Horsepower

One horsepower is equal to 746 watts. SincePower = Torque × Speed, horsepower is a measure ofa motor's torque and speed capability (e.g. a 1 HPmotor will produce 35 lb-in. at 1800 rpm).

I/O: Input/Output

The reception and transmission of informationbetween control devices. In modern control systems,I/O has two distinct forms: switches, relays, etc.,which are in either an on or off state, or analogsignals that are continuous in nature such as speed,temperature, flow, etc.

Inertia

The property of an object to resist changes in velocityunless acted upon by an outside force. Higher inertiaobjects require larger torques to accelerate anddecelerate. Inertia is dependent upon the mass andshape of the object.

Inertial Match

An inertial match between motor and load is obtainedby selecting the coupling ratio such that the loadmoment of inertia referred to the motor shaft is equalto the motor moment of inertia.

Inrush Current

The current surge generated when a piece ofequipment such as a servo amplifier is connected toan AC line. This surge is typically due to the impulsecharging of a large capacitor located in theequipment.

Instability

Undesirable motion of an actuator that is differentfrom the command motion. Instability can take theform of irregular speed or hunting of the final restposition.

Limits

Motion control systems may have sensors calledlimits that alert the control electronics that thephysical end of travel is being approached and thatmotion should stop.

Logic Ground

An electrical potential to which all control signals in aparticular system are referenced.

Loop, Feedback Control

A control method that compares the input from ameasurement device, such as an encoder ortachometer, to a desired parameter, such as a positionor velocity and causes action to correct any detectederror. Several types of loops can be used incombination (i.e. velocity and position together) forhigh performance requirements.

Master Slave Motion Control

A type of coordinated motion control where themaster axis position is used to generate one or moreslave axis position commands.

Motor, AC

A device that converts electrical alternating currentinto mechanical energy. Requires no commutationdevices such as brushes. Normally operated offcommercial AC power. Can be single or multiplephase.

Oscillation

An effect that varies periodically between two values.

PLC

Programmable Logic Controller. Also known as aprogrammable controller, these devices are used formachine control and sequencing.

Power

The rate at which work is done. In motion control,Power = Torque × Speed.

Pulse Rate

The frequency of the step pulses applied to a step-permotor driver. The pulse rate divided by theresolution of the motor/drive combination ( in stepsper revolution) yields the rotational speed inrevolutions per second.

Ramping

The acceleration and deceleration of a motor. Mayalso refer to the change in frequency of the appliedstep pulse train.

Rated Torque

The torque producing capacity of a motor at a givenspeed. This is the maximum continuous torque the

BDS4 GLOSSARY

G-3

motor can deliver to a load and is usually specifiedwith a torque/speed curve.

Regeneration

The action during motor braking, in which the motoracts as a generator and takes kinetic energy from theload, converts it to electrical energy, and returns it tothe amplifier.

Repeatablity

The degree to which the positioning accuracy for agiven move performed repetitively can be duplicated.

Resolution

The smallest positioning increment that can beachieved. Frequently defined as the number of stepsor feedback units required for a motor's shaft to rotateone complete revolution.

Resolver

A position transducer utilizing magnetic coupling tomeasure absolute shaft position over one revolution.

RMS Current

Root mean square current. In an intermittent dutycycle application, the RMS current is equal to thevalue of steady state current which would produce theequivalent resistive heating over a long period oftime.

Rotor

The rotating part of a magnetic structure. In a motor,the rotor is connected to the motor shaft.

Servo Amplifier/Servo Drive

An electronic device which produces the windingcurrent for a servo motor. The amplifier converts alow level control signal into high voltage and currentlevels top produce torque in the motor.

Servo System

An automatic feedback control system for mechanicalmotion in which the controlled or output quantity isposition, velocity, or acceleration. Servo systems areclosed loop systems.

Shunt Resistor

A device located in a servo amplifier for controllingregenerative energy generated when braking a motor.This device dissipates of "dumps" the kinetic energyas heat.

Single Point Ground

The common connection point for signal grounds in acontrol wiring environment.

Slew

In motion control the portion of a move made at aconstant non-zero velocity.

Speed Regulation

For a speed control system, speed regulation is thevariation in actual speed expressed as a percentage ofset speed.

Stiffness

Ratio of an applied force torque to change in positionfor a mechanical system.

Stator

The non-rotating part of a magnetic structure. In amotor the stator usually contains the mountingsurface, bearings, and non-rotating windings orpermanent magnets.

Tachometer

An electromagnetic feedback transducer whichproduces an analog voltage signal proportional torotational velocity. Tachometers can be either brushor brushless.

Torque

The rotary equivalent to force. Equal to the productof the force perpendicular to the radius of motion anddistance from the center of rotation to the point wherethe force is applied.

Velocity

The change in position as a function of time.Velocity has both a magnitude and direction.

BDS4 INDEX

Underlined Text, 2-2

Unpacking, 2-2

Unregulated DC Voltages, 2-6

Ventilation, 4-2

Warning, 2-1

Warranty Information, see Appendix A

bds4 s i s m - magna products

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